The new generation of the Toyota Century is currently being produced at the Tahara Plant in Japan. This SUV is hand-assembled meticulously by a team of 40 skilled workers, selected from 1,500 employees. To fulfill their tasks on the assembly line, these workers must excel in a rigorous three-part assessment.
Hiroki Tanaka – one of the selected workers – had to undergo a mandatory training course and pass a certification exam to earn a spot on the team. The exam consists of three parts: a basic skills assessment, a written test on the history of the Toyota Century, vehicle structure, and related topics. Finally, there is a practical examination to demonstrate proficiency in assembling this luxury car.
“The written exam was more challenging than the practical one, with 200 questions, but I managed to pass it for the first time by diligently reading books since my days as a student,” Tanaka said. “I have learned many new things, from the history of Toyota and Century to the unique high-quality manufacturing techniques of automobiles. It has been a priceless experience.”
This 35-year-old assembly worker has been with Toyota since 2007. A graduate of the Toyota Technical Skills Academy, he said he was thrilled to get started working on the Land Cruiser line because it is his dream car, and after retiring, he will buy one for himself.
His experience in assembling Land Cruiser frames has given him a better foundation for his current job, which is assembling the suspension components for the Century. Hiroki Tanaka’s job is particularly important because any error can be felt when the vehicle is in operation.
Precision is always a point of emphasis on Toyota vehicles, but with the high-end Century model, it is a requirement. While the Japanese carmaker allows for a 20% torque deviation from the specifications on their regular vehicles, this luxury SUV only allows for a 5% deviation.
Tanaka explains: “On any assembly line other than the Century, each belt screw or bolt is tightened tightly with a dedicated tool in one go. First, we tighten close to the required specification using a simple device. Finally, we use a digital torque wrench that loads the torque value on the computer, working by hand to achieve the final value.”
This mechanic may spend up to a minute tightening larger, longer parts – five times the time it takes for workers to tighten bolts and screws on other vehicles in 5 seconds. That means Toyota only produces three Centuries per day.
On the Toyota Century assembly line, these carefully selected workers are divided into four specialized departments: Trim (responsible for managing parts such as the control panel and roof); Chassis (in charge of installing the engine, suspension system, and PHEV battery pack); Final (final assembly, handling seats, doors, and windows); and Adjusting, monitoring the final steps such as adding engine coolant and brake systems.
Tiến Dũng (Forum.autodaily.vn)
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