South is where we build the Lexus RX 350. TMMC holds the distinction of being the only plant outside of Japan to manufacture a Lexus. South was constructed specifically for this task. It is a world unto itself, brimming with state-of-the-art technology, staffed by specially trained Team Members, and where the pursuit of perfection is carried out with a passion found nowhere else on earth.
Making History
In May, 2000, history was made when Toyota announced that TMMC was chosen as the first plant outside of Japan to manufacture the Lexus luxury brand of vehicles—the RX 330 SUV. Today, we build the third generation of that model, the RX 350. This RX has been the most popular in the Lexus lineup since its introduction, and TMMC’s production of approximately 80,000 RX’s annually supplies the entire North American market.
From Start to Finish
From start to final inspection, it takes approximately 24 hours of elapsed time to assemble a single Lexus RX 350. As each vehicle makes its way through the 1.3 million square feet that make up the South plant, it will pass from the Body Shop to Plastics to Paint and then Assembly—where approximately 2000 parts and sub-assemblies are precision-fitted. Along the way, each vehicle will also undergo numerous inspections by both machine and human eye and touch.
Through the Eyes of the Customer
The keys to Lexus brand quality starts with the Lexus mindset: build each vehicle as if it were your own. Team Members themselves are trained to the highest standards in the industry and must be certified in a specific process before they can touch a vehicle on the line. Each process has been designed to ensure that every aspect of a Lexus looks, feels and even sounds like it belongs on a luxury automobile.
Painting a Masterpiece
The Paint Shop is where the luminous finish that is the hallmark of a Lexus vehicle is applied layer by layer—a process that takes more than ten hours. Specifically built for Lexus production, the Paint Shop is hermetically sealed to control dust and airborne particles. Team Members must pass through special ‘air showers’ before entering. All shell bodies are vacuumed by hand and undergo a series of intensive baths in preparation for the application of protective and paint layers that follow.
Choreographed Harmony
Team Members and robots complement each other at every stage of manufacture. Robots apply sealant in hard-to-reach areas, while Team Members apply sealant in visible areas with a craftsmanship borne of rigorous training and weekly re-testing. Approximately 240 feet of sealer is applied to each vehicle, sealing and insulating the cabin from the outside environment—protecting against water leaks and creating a library-quiet interior.
When is a Showroom Not a Showroom
When it is in South plant. Team Members walk through a replica of a Lexus Showroom on the way into the plant—a reminder of the special nature of the vehicle they’re building. The final inspection line is also reminiscent of a Lexus dealership, complete with polished wooden floors. Inspectors audit 293 items and every vehicle is Test driven on a Lexus-exclusive test track to ensure driving perfection before releasing it on its journey to its new owner.
Quick Facts
| Facilities |
Cambridge - 3 million sq ft Woodstock - 1.8 million sq ft |
| Investment | $5.6 billion CAD |
| Employment | 6,500 |
| Products | RX 350 |
Black and White
A unique system of bright fluorescent lighting against black walls brings to light even the tiniest imperfection. Team Members examine every inch of a vehicle. Any blemish, no matter how minute, is fixed. And every imperfection is recorded, traced to its source, and appropriate measures are then put in place to ensure it can never occur again.