Toyota's Body Construction

Toyota's Body Construction

Design Process



An early stage in the design process is the visualization of air flow over exterior surfaces. Using small clay models and advanced scientific test methods, aerodynamic properties are determined early in the development process... a critical first step in achieving superior performance, efficient fuel consumption, and precise handling control.



The structural framework takes shape through Computer-Aided-Design. Data from engineers working on various parts of the design can be integrated and overlaid... so they can see, for instance, how the door fits against the weatherstripping and the rocker panel, long before the first prototype is produced.

Fit and Finish



Perfect fit and finish begins with a flawless component. Each stamped piece of sheet steel is carefully checked by running a whetstone over the surface, which reveals any imperfections. Even something as minute as a speck of dust can leave a mark.



Large sub-assemblies come together on an automated framing line. What emerges is a highly rigid structure...completely accurate in assembly and consistent in quality.



Every two weeks, this main body gauge verifies the accuracy of the welded body. Over a thousand measurement points determine whether gaps and levelness are within strict specifications of plus or minus half a millimetre.

Corrosion Protection



To ensure compliance with Toyota anti-corrosion standards, which are among the toughest in the industry, metal components spend weeks in salt spray chambers during the new model development process



During production, a special adhesive is applied robotically to the inside of the door hem, to safeguard an area susceptible to corrosion.



Toyota is foremost among manufacturers in applying anti-corrosion material early on in the painting process. PVC sealant is carefully applied to all seams in the metal... the area where rust normally first takes hold.



A thick layer of rust-inhibiting PVC is applied by robots over all floor panel joints. Rocker panels, wheel arches and the leading edge of the hood are protected with a tough anti-chip coating. The entire exhaust system is made of stainless steel, for long lasting durability. Many competitors use simple galvanized steel, a cheaper and less enduring material.

Manufacturing Quality



All Toyota's manufacturing processes are designed around quality. For instance, with the famous Just-In-Time system, small batches of parts are produced as needed, and then are used right away. If a problem develops, it is discovered quickly...before hundreds or even thousands of faulty components have been produced.



To ensure total quality, welds are constantly checked right at lineside. Every hour, a gas tank is destroyed with an air chisel, in the course of testing all the welds.



The human factor is a key ingredient all the way through the manufacturing process. Everyone is responsible for quality, never passing on a defect. The customer isn't some stranger in a distant dealership, it's a fellow team member a few feet away.

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