NUMMI Plant Tour

[TRD4ME / PARKSOFFROAD.COM]

I am going to be going on a tour of the NUMMI (New United Motor Manufaturing Inc.) where they make the Toyota Corolla, Toyota Tacoma and the Pontiac Vibe.

NUMMI began producing a truck, originally called the Hilux, in 1991. Four years later, the Hilux was redesigned and re-named the Tacoma. NUMMI now produces over 163,000 Tacomas a year.

NUMMI builds 17 models of the award-winning Tacoma, including a PreRunner Double Cab, 4x4 Double Cab, 4x2 Xtracab, PreRunner Xtracab, 4x4 Xtracab, S-Runner, 4x2 Regular Cab, PreRunner Regular Cab and 4x4 Regular Cab.

I will also be meeting with some of the production people, so I wanted to see if anyone had any questions that they wanted me to ask. Don't ask when we will see a solid axle, a diesel etc., I am looking for questions that are production related! Want to know how something is put together, how they do it etc., then post up your questions and I will try to get them answered.

I will be sure to get plenty of pictures!
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Questions so far:
-Frame cracks - dont know if we will get an answer

-Rust durability on older vs. newer vehicles. what has changed to make newer ones less rust resistant?

-Why is the steering wheel in the tacoma not the same as the 4runner.

-when will toyota come out with a vehicle to compete with the rubicon? ( I know this is in the works, but we will see what they know )

-are there any plans to put a v8 in the tacoma?

-do they know the cause of the R&P failures on 05+ vehicles?

-where does the new car smell come from?

-the dash rattle problem: why not a simple fix at the factory vs. a TSB repair later?

[SP Jon M3]

Ask them why a couple of Tacoma's had motor mounts break at the frame welds?

http://www.tacomaterritory.com/forum...ad.php?t=49360

[Valkyrie]

That seems like a very timely inquiry.

[TRD4ME / PARKSOFFROAD.COM]

Originally Posted by SP Jon M3

Ask them why a couple of Tacoma's had motor mounts break at the frame welds?

http://www.tacomaterritory.com/forum...ad.php?t=49360

While I dont get to read on the forums as much as I wish I could, I have seen the threads about this. I can certainly ask them, but I think we all know what the response will be!

Maybe I can print out a few pics to show them!

[Sisyphus]

Ask them what they do for quality control. Seems like there have been a few issues that have slipped through the cracks.

Also ask them what they are going to create to compete with the Jeep Rubicon package, or are they giving up on the off-road enthusiast market? How about a 3.0 or 4.0:1 low range, front locker and upgraded skid plate package? (Especially fuel tank and front skids )

Also ask them if they could box the whole frame, like the Prado, especially the rear portions. I think those are some very real goals for Toyota to hit. Obviously we will never see the solid axle diesel, but we should get something better than just an electronic rear locker.

[justinh]

Originally Posted by SP Jon M3

Ask them why a couple of Tacoma's had motor mounts break at the frame welds?

http://www.tacomaterritory.com/forum...ad.php?t=49360

I don't think they will be able to answer that since the frames aren't even built there or by them. It would be nice though. Unfortunately I doubt anyone in that factory even looks at the frames from a QC standpoint.

[deasley]

I have toured the NUMMI and the indiana plant and also the San Antonio plant aswell and unless you mount a very good spy cam somwhere on your person there will be no photos taken. everything about their manufactering processes are very top secret. you will find that the tour is great but there are many things they will not show you

[ocdropzone]

Definitely ask them about Chris's (sisyphus) questions. If you can print out some of the pictures of Cell4soul's frame and motor mount issues.
My question would be why they went to a worthless piece of plastic under the gas tank and are calling it a skid plate?
I am jeolous, that would be a cool experience.

Deasley is right about the pictures. I work for a large chip maker, your processor was probably made by it, easy one to guess if it is not AMD. Anyway due to process and intellectual property reasons, ISO compliance, you will more than likely not get a camera in. We have to submit a Camera pass request through security and have a very good reason to have any form of recording device in a production area. Very easy to get canned for it, all visitors must be escorted and 99% never see the fab where we actually make stuff.

Hopefully they are a little more flexible...Have a great time and post what you find out, hopefully you get straight answers and not the usually song and dance about they can't comment on any quality issues, my guess is you will hear they are not aware of it...

[deasley]

honestly it will be an experience you will never forget hopefully they will let you get close to the sheet metal stamps they weigh about 25 tons and it moves around pretty fast on one of the precision cranes operated by computer. also the painting area is something not to miss you have to change into a clean suit to go in there its fregin awsome. oh also in just about every area of the plant the robotic welders are running and though they are very pretty look at watch out for the molten embers flying they are not you normal welding embers. you will have to where a long sleeve shirt and a hard hat because of this if your not wereing one they give you these goofy pull on sleeves. oh and don't worry about the goofy disney jingles playing all around they will explain it to you on the head phones you were during the tour.

[hytenor]

Originally Posted by TRD4ME / PARKSOFFROAD.COM

While I dont get to read on the forums as much as I wish I could, I have seen the threads about this. I can certainly ask them, but I think we all know what the response will be!

Maybe I can print out a few pics to show them!

O boy, I would hammer them with this issue! As for the frames being made off-site...bull shit! don't they LOOK at the damn things?? is their NO quality control??! Any idiot can look at those welds and be able to see they are crap, sheesh. Find someone at the upper end of the feeding chain and bring this up explaining that thousands of Toyota owners and potential owners are reading about this right now...and...will continue to because we won't drop this issue until Toyota step up and does the right thing.

8,600+ hits on that thread...so far...

Maybe the mag needs a "WTF, Toyota??" section.

[bradleyem]

You might also want to ask them about the transmission noises and problems from these threads:

http://www.ttora.com/forum/showthread.php?t=49939

http://www.ttora.com/forum/showthread.php?t=50607

[hytenor]

Originally Posted by bradleyem

You might also want to ask them about the transmission noises and problems from these threads:

http://www.ttora.com/forum/showthread.php?t=49939

http://www.ttora.com/forum/showthread.php?t=50607

great idea.

and...the busted ring gears from the '05s...might be nice to hear what the actual cause was on those.

[TACODOC]

Originally Posted by hytenor

great idea.

and...the busted ring gears from the '05s...might be nice to hear what the actual cause was on those.

No shit!

[hytenor]

Originally Posted by 05TACODOC

No shit!

I believe most all of them have been taken care of due to AllPro's winning of their arbitration. All anyone else has to do is refer to that case (get the # from Sarah) when dealing with your local DSM and that should be the end of it.

[TACODOC]

Mine was covered, I just wonder what the deal was? Bad steel? Bad process? Which MFG date vehicles have this problem to look forward to?

[TRD4ME / PARKSOFFROAD.COM]

I am guessing that these people are not mechanics, nor do they deal with warranty work much. They work their stations doing the same thing over and over again on the assembly line. The engines, transmissions and such most likely come to the plant assembled so I dont think they will be able to answer questions about noises or durablilty, same with the R&P questions.

I can ask how the frames are checked prior to use in regards to bad welds, you would think that would be a visual inspection item. Questions like what makes that "new car" smell, or why cant we get specific options without a package (such as a base truck with a locker and xyz gear ratio) would be questions they could answer.

[SP Jon M3]

Originally Posted by Sisyphus

Also ask them what they are going to create to compete with the Jeep Rubicon package, or are they giving up on the off-road enthusiast market? How about a 3.0 or 4.0:1 low range, front locker and upgraded skid plate package? (Especially fuel tank and front skids )

I don't think this is a question for the plant that builds the truck. That would be a question for the design/engineering group. The plant just receives the "blueprints" from Toyota and then builds the vehicle for them.

Originally Posted by Sisyphus

Also ask them if they could box the whole frame, like the Prado, especially the rear portions. I think those are some very real goals for Toyota to hit. Obviously we will never see the solid axle diesel, but we should get something better than just an electronic rear locker.

Well, both the FJC and the 4R have fully boxed frames. Only the Tacoma has the prado derived frame which is partial boxed, then C-channel. And I'm not trying to argue with you, I too wish the Tacoma had a fully boxed frame.

[jbstrd]

Not sure if this would be a question for them but, "Will we ever see a V8 Tacoma?"

Jason

[equin]

Originally Posted by SP Jon M3

I don't think this is a question for the plant that builds the truck. That would be a question for the design/engineering group. The plant just receives the "blueprints" from Toyota and then builds the vehicle for them.


Well, both the FJC and the 4R have fully boxed frames. Only the Tacoma has the prado derived frame which is partial boxed, then C-channel. And I'm not trying to argue with you, I too wish the Tacoma had a fully boxed frame.

Or if not a fully boxed frame, at least a much stronger c-channel frame. The older FJ40's are strong, thick c-channel, as are the 80-96 F150/Broncos.

[hytenor]

Originally Posted by equin

Or if not a fully boxed frame, at least a much stronger c-channel frame. The older FJ40's are strong, thick c-channel, as are the 80-96 F150/Broncos.

the mid C channel portoin of the frame is very strong, 3/16" hi-grade steel...it's the nose-end boxed portion that is the same basic thing the early Tacos have.

[Gadget]

Maybe ask why my 96 4Runner with 170,000 miles on it, driven in the MD snow with salted roads, and off roaded regularly, has way less corrosion and rust then my 2 year old Tacoma that is never driven in the snow or off roaded??????

The plating on all the fasteners is a much less quality then the 96 4Runner, and most of them are rusting. Why?

All the points under the hood where the grounding straps bolt are all corroaded. Why?

There is a lot of rust on the frame, mostly in the C channel area on the inside and where the seam is. There is a huge rust area on the frame on the passenger side under the strut tower mount. Lots of rust on the forward section of the suspension on the passenger side. Why?

Lastly, the steering wheel. Both my 4Runners the steering wheel is perfectly round. The Tacoma is anything but round. I know that is a small thing, but it damn sure bugs me. Why?

Other then those few things, and the crappy tranny, brittle chipping paint, squeeky leaf springs, I love the truck. Really it is a nice truck, but the quality clearly is not like it was on my 96 4Runner.

[ryguy]

question for you guys.. but isnt this just the manufacturing plant not R&D. They just put the stuff togethor, they dont trouble shoot. Just wondering, Cause I dont think they have anything to do with what Toyota wants. Toyota tells them to make this widget and then they do. I would love to have the reasons why things arent done properly.. Bla!

[Gadget]

Originally Posted by ryguy

question for you guys.. but isnt this just the manufacturing plant not R&D. They just put the stuff togethor, they dont trouble shoot. Just wondering, Cause I dont think they have anything to do with what Toyota wants. Toyota tells them to make this widget and then they do. I would love to have the reasons why things arent done properly.. Bla!

Yep, you are right.

They may want to know about this frame problem so they can tell their quality control folks to sniff that over as the frames come in the door so they don't put a bad one on the road.

[TRD4ME / PARKSOFFROAD.COM]

Originally Posted by Gadget

Maybe ask why my 96 4Runner with 170,000 miles on it, driven in the MD snow with salted roads, and off roaded regularly, has way less corrosion and rust then my 2 year old Tacoma that is never driven in the snow or off roaded??????

The plating on all the fasteners is a much less quality then the 96 4Runner, and most of them are rusting. Why?

All the points under the hood where the grounding straps bolt are all corroaded. Why?

There is a lot of rust on the frame, mostly in the C channel area on the inside and where the seam is. There is a huge rust area on the frame on the passenger side under the strut tower mount. Lots of rust on the forward section of the suspension on the passenger side. Why?

Lastly, the steering wheel. Both my 4Runners the steering wheel is perfectly round. The Tacoma is anything but round. I know that is a small thing, but it damn sure bugs me. Why?

Other then those few things, and the crappy tranny, brittle chipping paint, squeeky leaf springs, I love the truck. Really it is a nice truck, but the quality clearly is not like it was on my 96 4Runner.

Yes, I can ask them about the rust resistance of newer vs older trucks. I can also sky why they use a different steering wheel, they may know, but it may be just what they are told to use!

[dylanscott]

Ask why the stinkin dash rattle?! You'd think they'd have that one figured out by now anyway.

[ryguy]

Originally Posted by Gadget

Yep, you are right.

They may want to know about this frame problem so they can tell their quality control folks to sniff that over as the frames come in the door so they don't put a bad one on the road.

ooo that would be great!! I need that since Im going to start racing my truck! Stock class here I come!

[91toyota4x4]

Man after reading this thread I am glad my truck was made in Japan.

[Valkyrie]

meh, don't make it worse than it really is... beside, Japan is responsible for the 3.slow you have, so I guess no one is perfect.

[ARB1977]

Originally Posted by Gadget

Maybe ask why my 96 4Runner with 170,000 miles on it, driven in the MD snow with salted roads, and off roaded regularly, has way less corrosion and rust then my 2 year old Tacoma that is never driven in the snow or off roaded??????

The plating on all the fasteners is a much less quality then the 96 4Runner, and most of them are rusting. Why?

All the points under the hood where the grounding straps bolt are all corroaded. Why?

There is a lot of rust on the frame, mostly in the C channel area on the inside and where the seam is. There is a huge rust area on the frame on the passenger side under the strut tower mount. Lots of rust on the forward section of the suspension on the passenger side. Why?

Lastly, the steering wheel. Both my 4Runners the steering wheel is perfectly round. The Tacoma is anything but round. I know that is a small thing, but it damn sure bugs me. Why?

Other then those few things, and the crappy tranny, brittle chipping paint, squeeky leaf springs, I love the truck. Really it is a nice truck, but the quality clearly is not like it was on my 96 4Runner.

Old school is just better.

[91toyota4x4]

Originally Posted by valkyrie

meh, don't make it worse than it really is... beside, Japan is responsible for the 3.slow you have, so I guess no one is perfect.

I'll take the 3.0 over cracked, rusty frames and trashed gears any day!