The new Yaris Hybrid: TMMF manufactures the only full hybrid in the b-segment

Originally conceived as a highly compact plant -with limited parts stock and an optimised production line layout contributing to a notably streamlined manufacturing process- Toyota Motor Manufacturing France (TMMF) has been building the Yaris for over a decade.

The Yaris has already established a reputation for outstanding levels of Quality, Durability and Reliability. With the addition of further derivatives including the new Yaris Hybrid, TMMF remains committed to delivering vehicles with the highest levels of built-in quality in the B-segment.

Yaris Hybrid manufacturing has introduced further complexity and new challenges to the assembly process, and increased the range of Yaris models produced on the same line to a record high of 62 varieties at TMMF.

On average, each Yaris requires the assembly of over 2,600 parts, with around 80% of total parts common to the standard Yaris and the Yaris Hybrid. However, there are 400 new, hybrid-specific components, and 40% of all assembly processes for the Yaris Hybrid are either new, or required adaptation. Because of the plant's very compact size, stock management has had to be further optimised, and sequenced delivery organised for a larger number of parts.

Over 4,000 hours of Yaris Hybrid assembly training was provided to TMMF members, with a focus on three key areas: assembly techniques for new on-line parts, part variety recognition amongst components of a similar kind, and the meeting of key quality targets. Specific attention was paid to the inverter assembly, this component being highly sensitive to dust and body intrusion.

Specific safety training in how to handle high voltage parts was provided to some 50 plant members, and new safety procedures resultant from the silent running of vehicles in EV drive mode established. In addition, a new, hybrid-specific, high quality pearl white paint finish was introduced at TMMF for the first time.

Despite these changes, and additional logistic complexities such as sequencing delivery of a higher number of parts, the continuous Kaizen and production line streamlining inherent in the principles of the Toyota Production System have meant that, overall, the Yaris Hybrid takes not much longer to produce than the standard Yaris.

Befitting the Yaris Hybrid's environmental credentials, the TMMF plant itself has seen the recent implementation of numerous environmental initiatives to minimise waste and lower power and water consumption.

Waste production has been reduced by 34% over the last 10 years, and since 2007, 100% of waste is recycled or recovered.

Through Toyota's continuous improvement activities, the plant has also achieved average savings per car of 27% in energy, 67% in water and 48% in VOC (the volatile organic compounds produced through solvent usage) over the same period.

In 2011, 60% of the plant's total water needs were covered by either rainwater — collected in a specific 6,200 m3 basin, or by recycling used water from production processes at an in-house waste water treatment station.

A 1,020 m2 photovoltaic membrane has been installed on the plant roof, providing half of the electricity needed for the administration building. And the press shop incorporates a 400 m2 solar wall, pre-heating the outside air to save on heating energy and CO₂ emissions.

Dispensing with the need for packaging materials, all car components are delivered from suppliers to the plant in 400,000 reusable plastic boxes, reused for over 10 years.

With TMUK already assembling the full hybrid Auris, the start of Yaris Hybrid production at TMMF makes Toyota the only manufacturer to have two full hybrid technology production facilities in Europe, reinforcing the company's commitment to local manufacturing of high technology vehicles.

The plant currently manufactures around 1,000 cars a day, corresponding to one new Yaris driving out of the line every 68 seconds. TMMF expects to produce around 200,000 vehicles in 2012, of which 25% hybrid.