Immersive Manufacturing Journey: Exploring Toyota's Digital Factory via the Toyota Virtual Plant Tour
In the heart of Toyota City, Aichi, the staff behind the Toyota Kaikan Museum have taken the initiative to bring the Toyota manufacturing experience to the digital age. The Toyota Virtual Plant Tour project, born out of the COVID-19 pandemic, aims to continue Kiichiro Toyoda's passion for sharing Toyota's manufacturing and the people involved.
The virtual tour is a testament to Toyota's commitment to continuous improvement (kaizen) and human-centered manufacturing (monozukuri). It offers an immersive experience that highlights manufacturing processes while emphasizing the people and craftsmanship behind them.
The tour emphasizes Toyota Production System (TPS)-led efforts and ongoing improvements in both manufacturing and sales genba (work sites), illustrating a culture of constant refinement and problem-solving derived from the kaizen philosophy. It highlights real efforts to improve quality, efficiency, and worker involvement across different production areas.
The content stresses the artisanship and skills of Toyota’s master craftsmen who bring precision and quality to every vehicle part. The stories of individual workers and their dedication are foregrounded, reflecting Toyota’s commitment to valuing its workforce and fostering a manufacturing environment focused on people’s contributions.
By using a virtual format, Toyota allows users to explore complex manufacturing processes accessibly and engagingly, inviting viewers to appreciate the nuances of both machinery and human effort. This approach aligns with Toyota’s desire to make manufacturing a place where people understand and connect with the process, reinforcing their corporate mindset of collaboration and care.
The Toyota Virtual Plant Tour project was led by Akiko Kita as Group Manager. The team spent a year constructing the website, interviewing more than 40 people for the project. After the suspension of in-person tours, the staff received messages from customers expressing their desire to visit again.
Before the suspension, Toyota welcomed approximately 130,000 domestic and foreign visitors a year, with a total of 13.3 million people having toured their facilities. The virtual tour now offers an online experience of Toyota’s manufacturing facilities, known as the genba.
Toyota's strength lies in evolution through kaizen, and manufacturing is no exception. Oyaji Kawai, Executive Fellow Mitsuru Kawai, stated that Toyota's strength lies in evolution through kaizen. The virtual tour is a reflection of this, showcasing the dynamic nature of continuous improvement and embodies monozukuri through its human-centered storytelling and focus on craftsmanship.
The Toyota Virtual Plant Tour site is designed around "human-centered monozukuri", enabling viewers to experience manufacturing not only as a technical achievement but as a deeply human enterprise. The project team constantly sought input from those on the frontlines to ensure the virtual tour accurately reflects the spirit of Toyota's manufacturing culture and values.
The first automotive plant tour began in 1939 at Koromo, and the virtual tour continues this tradition, bringing Toyota's manufacturing culture to a wider audience. The project team hopes that the virtual tour will inspire visitors to appreciate the artistry and dedication that goes into every Toyota vehicle.
Sources: [1] Toyota Global - Newsroom. (2021, July 15). Toyota launches virtual plant tour. Retrieved from https://global.toyota/en/newsroom/corporate/33178196.html [2] Toyota Kaikan Museum. (n.d.). History. Retrieved from https://www.toyotakai.jp/en/history/ [3] Toyota Global - Newsroom. (2021, July 15). Toyota Virtual Plant Tour offers a closer look at the heart of Toyota manufacturing. Retrieved from https://global.toyota/en/newsroom/corporate/33178198.html
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