Overview of Overseas Production Affiliates

North America

CAPTIN TMMC TABC TMMK BODINE TMMWV TMMI TMMAL TMMTX SIA TMMMS NUMMI

CAPTIN

Panoramic view

Panoramic view

Overview

Company name
Canadian Autoparts Toyota Inc.
(CAPTIN)
Start of production
February 1985
Site area
90,000 m2
Main business
Aluminum wheel production
Production results for 2011
Aluminum wheels:1,165,000 units
No. of employees*
307
Equity participation
TMC: 100%
*
As of December 31, 2011

Events

Year
Month
Events
1983
March
Company established
1985
February
Production commenced (240,000 units per year)
1989
November
Capacity increased (480,000 units per year)
1992
October
Second capacity increase (720,000 units per year)
1996
December
Cumulative production reached 5 million units
1998
January
Local Canadian president appointed (the first non-Japanese president of Toyota's direct overseas affiliate)
March
Third capacity increase (960,000 units per year)
1999
September
Fourth capacity increase (1.2 million units per year)
2002
February
Cumulative production reached 1 billion units
2004
August
Fifth capacity increase (1.44 million units per year)
2007
June
Sixth capacity increase (1.68 million units per year)

TMMC

Panoramic view

Panoramic view

Overview

Company name
Toyota Motor Manufacturing Canada Inc
(TMMC)
Start of production
November 1988
Site area
Cambridge Plant: 1,500,000 m2
Woodstock Plant: 3,750,000 m2
Business activities & products
Vehicle production
Cambridge Plant: Corolla, Matrix, RX 350
Woodstock Plant: RAV4, RAV4 EV
Production results for 2011
413,000 vehicles
Number of employees*
6,990
Equity participation
TMC: 100%
*
As of December 31, 2011

Events

Year
Month
Events
1986
January
Company established
May
Construction of Cambridge South Plant commenced
1988
November
Corolla Sedan production commenced
1991
February
Corolla Sedan wins 'Best Vehicle Built in Canada' for three consecutive years
July
TMMC receives J.D. Power Gold Plant Quality Award (North America)
1995
May
TMMC receives J.D. Power Gold Plant Quality Award (North America)
October
Corolla A (L4) engine assembly commenced
1996
April
Cumulative vehicle production reaches 500,000 units
May
TMMC receives J.D. Power Gold Plant Quality Award (North America)
1997
August
Cambridge North Plant begins operations
1998
June
Camry Solara production commenced
1999
September
Cumulative vehicle production reaches 1 million units
2000
February
Solara Convertible production commenced
2001
May
TMMC receives J.D. Power Gold Plant Quality Award (North America)
2002
January
Matrix production commenced
2003
September
Lexus RX 330 production commenced
2004
June
Cumulative vehicle production reaches 2 million units
2007
September
Cumulative vehicle production reaches 3 million units
December
Engine assembly discontinued (transferred to and consolidated at TMMWV)
2008
November
Woodstock Plant operations commenced, RAV4 production commenced
2010
August
TMMC wins J.D. Power Gold Plant Quality Award (North and South America)
2011
June
TMMC wins J.D. Power Platinum Award (Cambridge South Factory)

TABC

Panoramic view

Panoramic view

Overview

Company name
TABC, Inc.
(TABC)
Start of production
January 1972
Site area
110,000 m2
Business activities & products
Production of steering columns, stamped parts, and other parts
Production results for 2011
Steering columns: 115,000 units
Stamped parts: 8.6 million units, etc.
Number of employees*
474
Equity participation
TMC: 100% (including affiliates)
*
As of December 31, 2011

Events

Year
Month
Events
1971
July
Truck bed production outsourcing agreement entered into with Toyota Motor Sales, U.S.A. and Atlas
1972
January
Hilux rear deck production commenced
1974
February
Toyota Motor Sales, U.S.A. acquires Atlas and establishes LBF
1979
April
Name changed to TLBF
1980
March
Name changed to TMM
1986
April
Name changed to TABC
October
Stamped parts production for NUMMI and TMMC commenced
1989
June
Catalytic converter production commenced
1991
May
Catalytic converter division separated off and established as an independent company (CCP established; production discontinued in April 2011)
 
Outsourced truck manufacturing commenced (for supply to NUMMI)
1996
May
Steering column production commenced
2000
June
Truck business separated off and TMMCA established
2004
October
Hino truck production commenced
2005
January
Tacoma truck bed bridge production discontinued
2008
July
Hino truck production discontinued
2010
March
Passenger car stamped parts production for NUMMI discontinued
2011
April
Catalytic converter production discontinued

TMMK

Panoramic view

Panoramic view

Overview

Company name
Toyota Motor Manufacturing, Kentucky, Inc
(TMMK)
Start of production
May 1988
Site area
5,300,000 million m2
Business activities & products
Vehicle and powertrain (engines and axles) production
Production vehicles: Camry, Camry Hybrid, Avalon and Venza
Engines: AR (L4) engine for the Camry and 2GR (V6) engine for the Camry, Avalon, and Sienna
Production results for 2011
Vehicles: 315,000 vehicles
Engines: 415,000 units
Number of employees*
7,581
Equity participation
TMC: 100% (including affiliates)
*
As of December 31, 2011

Events

Year
Month
Events
1986
January
TMMK established (TMM at the time of establishment)
1988
May
Production commenced with the Camry Sedan
1989
December
L4 engine assembly commenced
1992
March
Powertrain plant Phase II (for L4 engine machining) completed
1994
September
Avalon production and V6 engine assembly commenced
1996
August
V6 engine machining commenced (crankshafts, cams, connecting rods)
October
Name changed from TMM to TMMK in conjunction with establishment of TMMNA (in the U.S.A.)
1997
May
V6 engine machining commenced (engine blocks, cylinder heads)
August
Sienna production commenced
2001
April
An American president appointed
2002
December
Sienna production discontinued (transferred to TMMI in the U.S.A.)
2003
July
Solara production commenced
2006
October
Camry Hybrid production commenced
2008
November
Production of the Venza (successor to the Solara) commenced

BODINE

Troy Plant

Troy Plant

St. Louis Plant

St. Louis Plant

Tennessee Plant

Tennessee Plant

Overview

Company name
Bodine Aluminum, Inc.
(BODINE)
Start of production
January 1993
Site area
Troy Plant 320,000 m2
St. Louis Plant 40,000 m2
Tennessee Plant 800,000 m2
Business activities & products
Aluminum castings production
Troy Plant: cylinder heads, cylinder blocks
St. Louis Plant: Engine brackets and other parts
Tennessee Plant: Automatic transmission cases, cylinder blocks
Production results for 2011
Cylinder heads: 1.61 million units
Cylinder blocks: 1.08 million units
Transmission cases: 260,000 units
Number of employees*
1,011
Equity participation
TMC: 100% (including affiliates)
*
As of December 31, 2011

Events

Year
Month
Events
1912
 

Company established
1960
 
Relocated to current St. Louis Plant
1990
January
Acquired by TMCS (U.S.A.)
1993
January
Production commenced at Troy Plant (Camry 5S engine cylinder heads and intake manifolds)
April
Troy Plant opening ceremony held
1996
October
5S engine cylinder head cumulative production reaches 1 million units
1997
April
Production of Camry 1MZ engine (V6) cylinder head and block and intake manifold commenced
1998
November
Corolla 1ZZ engine lower case production commenced; Cylinder block production commenced in March 1998 and cylinder head production commenced in May 1999
2001
September
5S engine cylinder head replaced by 2AZ engine cylinder head
2003
May
Production of Camry 2UZ engine cylinder head commenced
2005
December
Tennessee Plant commences production (2GR engine cylinder blocks)
2007
July
Production of 6-speed automatic transmission case and housing commenced
December
1ZZ engine lower case replaced by 2ZR engine lower case
2008
December
Production of RAV4 2AR engine cylinder head and cylinder block commenced
2010
October
6-speed automatic transmission housing production discontinued (production transferred to AAC)

TMMWV

Panoramic view

Panoramic view

Overview

Company name
Toyota Motor Manufacturing, West Virginia, Inc.
(TMMWV)
Start of production
November 1998
Site area
930,000 m2
Business activities & products
Production of engines and automatic transmissions: ZR (L4) engine for the Corolla, 2GR (V6) engine for the Sienna, Highlander, Lexus RX and RAV4, and six-speed automatic transmissions for the Avalon, Camry (V6), Venza (V6), Lexus RX, and Sienna
Production results for 2011
Engines: 494,000 units
Transmissions: 259,000 units
Number of employees*
1,069
Equity participation
TMC: 100% (including affiliates)
*
As of December 31, 2011

Events

Year
Month
Events
1996
May
Company established
1998
November
Corolla ZZ L4 engine production commenced
1999
August
Camry MZ V6 engine production commenced
2001
May
Production of Camry and Solara automatic transmissions commenced
2003
August
Production of MZ engine and automatic transmission for the Lexus RX commenced
2005
December
Automatic transmission gear production commenced
2007
January
MZ engine replaced by GR engine
July
Production of Camry and Avalon six-speed automatic transmissions commenced
December
ZZ engine replaced by ZR engine
2009
September
Five-speed transmission production discontinued (cumulative production: 2,743,000 units)

TMMI

Panoramic view

Panoramic view

Overview

Company name
Toyota Motor Manufacturing, Indiana, Inc.
(TMMI)
Start of production
February 1999
Site area
4,400,000 m2
Business activities & products
Vehicle production: Sequoia, Sienna, and Highlander
Production results for 2011
248,000 vehicles (annual production capacity)
Number of employees*
4,780
Equity participation
TMC: 100% (including affiliates)
*
As of December 31, 2011

Events

Year
Month
Events
1996
February
Company established
1999
February
Tundra production commenced
2000
September
Sequoia production commenced
2001
May
Tundra wins J.D. Power No. 1 award for two consecutive years
June
Tundra has highest performance in its category in IIHS crash test results
2002
May
Tundra wins J.D. Power No. 1 award for three consecutive years
2003
January
Sienna production commenced. Operations at No. 2 plant commenced
2006
May
Sequoia wins J.D. Power award for best initial quality in Large Multi-Activity Vehicles
2007
May
Sequoia wins J.D. Power award for best initial quality in Large Multi-Activity Vehicles
2008
July
Review of North American production structure announced; Tundra production transferred to TMMTX and Highlander introduced in October 2009
August
Tundra production discontinued (consolidated at TMMTX)
2009
October
Highlander production commenced

TMMAL

Panoramic view

Panoramic view

Overview

Company name
Toyota Motor Manufacturing, Alabama, Inc.
(TMMAL)
Start of production
April 2003
Site area
810,000 m2
Business activities & products
Engine production:
1GR (V6) engine for the Tacoma, UR (V8) engine for the Tundra and Sequoia, and AR (L4) engine for the RAV4, Sienna, Venza, Camry, and Highlander
Production results for 2011
231,000 units
Number of employees*
1,035
Equity participation
TMC: 100%(including affiliates)
*
As of December 31, 2011

Events

Year
Month
Events
2001
June
Company established, ground-breaking ceremony conducted
2003
April
Tundra 2UZ (V8) engine assembly commenced
May
Connecting rod and crank processing commenced
June
Head cam processing commenced
August
Block processing commenced
2005
July
1GR (V6) engine assembly commenced
2006
December
Tundra 3UR (V8) engine production commenced
2008
January
Cumulative production reaches 1 million units (450,000 2UZ engines, 350,000 1GR engines, and 200,000 3UR engines)
2009
April
2UZ engine replaced by 1UR engine
2011
September
AR (L4) engine production commenced

TMMTX

Panoramic view

Panoramic view

Overview

Company name
Toyota Motor Manufacturing, Texas, Inc.
(TMMTX)
Start of production
November 2006
Site area
8,000,000 m2
Business activities & products
Vehicle production: Tundra, Tacoma
Production results for 2011
149,000 vehicles
Number of employees*
2,866
Equity participation
TMC: 100% (including affiliates)
*
As of December 31, 2011

Events

Year
Month
Events
2003
March
Company established
2006
November
Tundra production commenced
2008
November
TMMI Tundra production consolidated at TMMTX
2010
July
Tacoma production commenced (transferred from NUMMI)

SIA

Exterior view

Exterior view

Overview

Company name
Subaru of Indiana Automotive, Inc.
(SIA)
Start of production
Toyota Camry production commenced in February 2007
Site area
3,310,000 m2
Business activities & products
Production of vehicles and engines
Production vehicles: Camry and Subaru vehicles
Production results for 2011
79,000 Toyota vehicles
Number of employees*
3,617
Equity participation
100% locally owned (100% owned by Fuji Heavy Industries Ltd.)
*
As of December 31, 2011

Events

Year
Month
Events
1987
March
Company established as a joint venture with Fuji Heavy Industries Ltd. and Isuzu Motors Ltd.
1989
September
Production of Subaru's Legacy and an Isuzu pick-up truck commenced
1995
March
Car side obtains ISO 9002 certification
1996
March
SUV side obtains ISO 9002 certification
1997
March
Cumulative vehicle production reaches 1 million units
1998
November
ISO 14001 certification obtained
2002
April
Cumulative production reaches 2 million vehicles
2006
October
Receives EPA WasteWise Gold Achievement Award in New Partner category
2007
February
Camry production commenced
April
Camry line-off ceremony conducted
November
Receives EPA WasteWise Gold Achievement Award in Industrial Material Recycling category
2008
October
Receives EPA WasteWise Gold Achievement Award in Climate Change category
2009
September
Cumulative production reaches 3 million vehicles
2010
March
Receives EPA WasteWise Gold Achievement Award for 2009 in Community Involvement category

TMMMS

Panoramic view

Panoramic view

Overview

Company name
Toyota Motor Manufacturing, Mississippi, Inc.
(TMMMS)
Start of production
October 2011
Site area
7,000,000 m2
Business activities & products
Vehicle production: Corolla
Production results for 2011
2,000 vehicles
Number of employees*
1,522
Equity participation
TMC: 100% (including affiliates)
*
As of December 31, 2011

Events

Year
Month
Events
2007
April
Company established
2011
October
Corolla production commenced

NUMMI

Exterior view

Exterior view

Overview

Company name
New United Motor Manufacturing, Inc.
(NUMMI)
Start of production
December 1984
End of production
April 2010
Site area
1,570,000 m2(as of production discontinuation in April 2010)
Business activities & products
Production of vehicles:
Corolla and Tacoma (production vehicles at the time of the end of production in April 2010)
Production results for 2011
28,000 vehicles in 2006 (peak)
Cumulative production: 7.74 million vehicles
Number of employees*
Approx. 4,000 (as of production discontinuation in April 2010)
Equity participation
TMC: 50%
*
As of December 31, 2011

Events

Year
Month
Events
1984
February
Company established
December
Production commenced with production of the first vehicle, GM Chevrolet Nova
1986
September
Corolla FX production commenced
1988
November
GM Chevrolet Prizm production commenced
1989
April
Toyota truck production agreement entered into
1991
August
Tacoma production commenced
2002
January
Production of Corolla and GM Pontiac Vibe commenced
June
Voltz production (for Japan) commenced
2004
February
Voltz production discontinued
2009
August
GM Vibe production discontinued
2010
April
Corolla and Tacoma production discontinued

This comment is included in light of the extremely important role that NUMMI played in the implementation of Toyota's global production policies and in Toyota's independent expansion into North America.

At the time, America's automakers were experiencing great difficulties resulting from the accelerating shift by buyers to compact cars in response to the second oil crisis in 1979. While Honda and Nissan decided to manufacture four-wheeled vehicles in the United States, Toyota's negotiations with Ford concerning joint production broke down. Consequently, Toyota established a joint venture business with General Motors, America's largest automaker, and produced its first vehicle at a plant in Fremont, California in 1984. Operations began with an initial joint venture term of 12 years from the start of production, but the arrangements continued for 25 years until August 2009. The joint venture by the top Japanese and American automakers was well received, and the mass media reported it as a symbol of both competition and cooperation between the auto industries of the two countries. At the International Labor Organization conference in 1986, the U.S. Secretary of Labor reported that NUMMI was a model plant for labor-management cooperation. Total production over 25 years was just under 5.7 million Toyota brand vehicles and a little more than 2.04 million GM brand vehicles, making a total of 7.74 million vehicles (see Table 2-1-3-2-1).

As a result of a shortfall in internal pension plan contributions and an insufficient response to the shift towards compact vehicles caused by rising gasoline prices as well as the effects of the subprime mortgage crisis and the collapse of Lehman Brothers, GM filed for protection under federal bankruptcy law in June 2009, and it essentially collapsed. GM was administered by the U.S. government and was forced to close domestic plants and reduce its labor force, and it decided to withdraw from NUMMI. Toyota considered whether to continue NUMMI following GM's withdrawal, but in the light of its production capacity in North America, decided that it had no choice but to discontinue production by NUMMI. The termination of production was announced in August 2009, and production ended in April 2010, closing the curtain on a 25-year history.

Production at NUMMI

Production at NUMMI

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