By Jamie White – Head of Communications

A tough challenge to plan, build and deliver two new models at the same time, has been completed by the Toyota UK team.

Toyota Manufacturing UK has proved itself up to the task, completing the simultaneous start of production of new Auris and Avensis at its Burnaston car plant.

Preparations for this exceptional programme began back in 2013, as plans for significant changes to both the vehicle ranges were put in place. Thanks to precision planning, the skills and commitment of the workforce and the support of dozens of suppliers, Burnaston has pulled off the feat.

At its most crucial point, the Derbyshire factory had to accelerate from building zero to 800 of the new cars a day, in the space of just 10 days.

The situation was all the more complex, because all versions of both cars – models at the heart of Toyota’s European sales – are built on the same production line, by the same teams, all the way from the press, through welding, paint shop and assembly. That includes Avensis saloons, Auris hatchbacks and Touring Sports wagon body styles of both models, with petrol, diesel and hybrid engines.

As well as the people skills, new equipment and ways of working had to be put in place throughout the plant, with manufacturing, painting and welding.

Add to this three new engines and a full powertrain upgrade to Euro 6 emissions standards and you have yet more changes to make. The introduction of Toyota Safety Sense preventive safety features even called for a redesign of Burnaston’s vehicle test track.

Success also relied on TMUK’s many suppliers all being ready to supply the necessary number of new parts, all validated for quality and performance, right on time.

With start of production secure, the focus now moves to the new models reaching the road. New Avensis is on sale now, with deliveries starting later this month; order books open for new Auris on July 1st, with first deliveries from September.

Douglas Stafford has been working in partnership with Toyota for several years, providing a bespoke mystery shopping and customer experience programme to include Telephone Mystery Shopping, Email Mystery Shopping and Video Mystery Shopping across its UK network.