TMMF started production of the Toyota Yaris in January 2001 with an initial annual production capacity of 150,000 units. The Yaris became the most produced single model in France seven times over 10 years. Since its introduction in 2021, the Yaris Cross has quickly established its strong position in the fast-growing European B-SUV market, and was the most produced single model in France in 2022 and 2023. The Yaris Cross now leads the European B-SUV segment and is Toyota’s top-selling model, with sales of 173,209 units in the first 10 months of 2024.

In 2023, the Valenciennes plant produced 273,788 units of both Yaris Cross and Yaris, the largest output amongst Toyota’s five vehicle assembly facitilies across Europe. 5,000 employees produce more than 1,200 Yaris Cross and Yaris vehicles every day, all of which are the hybrid versions. Toyota has made a total cumulative investment of 1.6 billion euros in TMMF’s facilities, including the capital investments for each new generation and model, as well as significant resources for continuously improving the manufacturing operation’s environmental performance.

Designed and developed to meet the needs of European customers in the B-segment SUV market, the projected powertrain mix of the new Yaris Cross is expected to be made up predominantly by the low CO₂ emission hybrid version, in line with the company’s plans for a 90% electrification mix by 2025.

Yaris Cross is the second model to be based on Toyota’s GA-B compact car platform and the 8th TNGA (Toyota New Global Architecture) model to be made in Europe*. Its start of production also marks further progress of Toyota’s localisation strategy.

Toyota’s vision for European localisation has further expanded this year, as Toyota Motor Manufacturing Poland (TMMP) started production of hybrid electric transmissions and electric motors, supplying the 1.5-litre TNGA petrol engine and full hybrid powertrain for both the Toyota Yaris and Yaris Cross.

Toyota has also invested to increase capacity and modernise its Toyota Motor Manufacturing Czech Republic (TMMCZ) plant in preparation for start of production of the Yaris, which was named The Car of the Year 2021, to satisfy increased demand.

The introduction of Yaris Cross production has brought the total employment at TMMF to almost 5,000.

* Toyota Motor Manufacturing France (Yaris and Yaris Cross), Toyota Motor Manufacturing Turkey (Toyota C-HR and Corolla Sedan), Toyota Motor Manufacturing UK in Burnaston (Corolla Hatchback and Touring Sports) and Toyota Motor Russia (Camry and RAV4)

Since its launch back in 1999 and winning the Car of the Year in 2000, Yaris has become an overwhelming success for Toyota, both in sales volume and in raising the brand's profile. Steadily growing from year to year, in 2019 the third-generation model achieved around 224,000 sales in Europe, accounting for around 22% of Toyota's European business and a segment share of just less than 8%.

The four millionth Yaris made in Europe is a fourth-generation model and features a fourth-generation Toyota Hybrid System to deliver the lowest fuel consumption and CO2 emissions in the segment [3.7l/100km and 85 g/km (WLTP)]. Toyota's engineers achieved this result whilst ensuring higher power (116 DIN hp) and greater fun to drive than the previous generation model.

The engineering team also maintained its safety DNA by making the new Yaris the safest car in its segment. In passive safety, Toyota received the 2020 SAFETYBEST award for the development and standard fitment of centre airbags in Yaris – a first in the European B-segment. Toyota's best-selling car also comes with the latest version of Toyota Safety Sense, including a number of segment-first active features as standard.

Looking forward, Yaris Cross will soon begin production alongside Yaris at TMMF.

TMMF has become the fourth plant in Europe to have introduced TNGA-based vehicle production after Toyota Motor Manufacturing Turkey (Toyota C-HR and Corolla Sedan), Toyota Motor Manufacturing UK in Burnaston (Corolla Hatchback and Touring Sports) and Toyota Motor Russia (Camry and RAV4). This investment further strengthens TME’s strategy to localise production and maximise manufacturing capacity. Toyota’s localisation strategy equally encompasses production of main vehicle components: the new Yaris is equipped with the latest generation of the 1.5L TNGA engine which is also made in Europe – at Toyota Motor Manufacturing Poland.

Additional investments and a second model on the way

An additional investment of €300 million, equivalent of half of TMMF’s initial investment, has been made to enable TNGA-based vehicle production. All the shop floors have been modernised with new equipment and technologies for improved ergonomics and performance. Amongst these works, one of the major expansions took place in the plastics shop with an additional surface of 3,500m² to accommodate new injection and paint lines, which in turn allow for in-house production of new plastic parts. TMMF expects the number of its permanent employees to reach 3,600 by the end of 2020, out of a total employment of 4,800.

Bringing TNGA philosophy to the compact car segment for the first time

The Toyota Yaris is at the heart of Toyota’s European success story enjoying sustained popularity and an excellent reputation for consistent innovation. In 2019, Yaris accounted for more than 20% of Toyota’s sales in Europe (224,368 units).

Designed for Europe and built in Europe as its first generation, the all-new Yaris features completely new, condensed proportions projecting a ‘ready-to-go’ character, ‘big-small’ packaging with roomy interior despite its compact exterior and an enhanced level of driving dynamics all thanks to the TNGA GA-B platform. The latest fourth generation Hybrid system offers longer EV driving capabilities, over 20% improvement in CO² emission and fuel economy compared to the current generation*¹ and yet increased responsiveness and drivability. The car is also designed to be the world’s safest compact car equipped with segment-leading active and passive safety systems. These include Toyota Safety Sense (TSS), a set of active safety technologies designed to help prevent or mitigate collisions across a wide range of traffic situations and the world’s first centre airbag in the compact car segment.

Production in compliance with COVID-19 measures

After five weeks of controlled production suspension in line with the COVID-19 lockdown measures taken in France, TMMF resumed its operations on 22 April. The initial production volumes were kept significantly lower compared to normal operations in order to focus on our number one priority - securing the Safety and Health of our employees and stakeholders by ensuring full compliance with the new hygiene and social distancing protocols and processes. Plant management will sustain its vigilance and ensure continued implementation of the Health and Safety measures against COVID-19.

*¹: Homologated measurements of the new generation Yaris in Worldwide Harmonised Light Vehicles Test Procedure (WLTP): CO2 emissions 85 g/km and fuel consumption 3.7 l/100km

The name of the new compact SUV, volume plans, and timing of introduction are to be announced at a future date. Only a stylised silhouette of the future car was shown at the event.

Thanks to the flexibility of the new GA-B platform, it can support vehicles of a different width, length, wheelbase or height.

The future vehicle will be built at Toyota Motor Manufacturing France (TMMF) in Onnaing, near Valenciennes, France, alongside the Toyota Yaris.

At first glance, it’s not so hard to spot the differences between the very first Toyota Yaris, produced on 31 January 2001, and the 3 millionth unit that rolled off the conveyer belt at TMMF, Toyota’s plant in Valenciennes, in the north of France. But when you look beyond the surface, you realise there is a lot more to those changes that meet the eye.

Under the hood 

The green credentials of the Toyota Yaris have significantly improved over the years. Comparing the first Toyota Yaris with the 3 millionth production milestone, a Yaris Hybrid, shows that both CO2 emission and fuel consumption levels have almost halved, even if weight and power output are up. The drag coefficient, which indirectly contributes to the car’s environmental performance, has improved from 0.30 to 0.286. Even the comparison to today’s petrol (non hybrid) version shows the Yaris engineers have kept up with the trend to reduce emissions and fuel consumption.

Head start thanks to eco design

A car doesn’t only draw its green credentials on the road: the way a car is produced is equally important. From the start TMMF has been designed to leave the smallest environmental footprint possible. In some workshops the storage areas are up to 10 times more compact compared to automotive industry standards with similar production output. Visually, the low building has been discretely integrated in the landscape. In 2007, TMMF was named one of the five sustainable plants of Toyota around the world, making the French plant an industrial benchmark for all other plants of the Toyota Group in terms of environmental performance.Head start thanks to eco design

Using 90% less water compared to 2002, making the plant autonomous in industrial water

TMMF has earned this acknowledgement after posting impressive results in water, waste and energy management, year after year. TMMF consumes 90% less industrial water today than in 2002, the first full year of production, and can run without drawing any water from the network – just using rain and recycled water. Sixty percent is rainwater that is collected in the two on-site basins with a combined volume of 16,000m³ and flows through the plant’s water treatment system to meet the required standards before usage in the production process. The remaining 40% is water that is recycled from the plant’s waste water after pre-treatment in the same water treatment system. As the water is processed both before and after usage in the production process, its quality exceeds the environmental norms and excess water can be safely released in the neighbouring river, the Scheldt.

100% waste is transformed, none is sent to landfill

TMMF has always been a plant with zero waste to landfill, but since 2007 it is successfully reclaiming 100% of its waste. Since 2001 any waste is carefully being either reused, recycled or recovered. Industrial oils and paint thinners are collected for reuse or regeneration; steel and aluminium make new raw materials; wood, cardboard and plastic wrappings are being recycled; the small amount of waste that is left is used as an alternative fuel source.

57% energy savings compared to 2002

Even though energy consumption was already at a very low level thanks to the compact building concept, TMMF managed to reduce the energy consumption by 57% compared to 2002 thanks to close monitoring, smart insulation, and saving on lighting to name just a few measures. Moreover, TMMF has been investing in pilot projects for renewables. Two and a half tons of CO2 per year are saved thanks to a photovoltaic membrane on the plant’s roof. Another saving of 18,4 tons of CO2 per year results from a solar wall that heats the outside air flowing into some of the workshops. Most recently, an existing gas boiler has been replaced with a biomass boiler, resulting in CO2 savings in the order of 1285 tons/year.

3 millionth Toyota Yaris for French customer

The 3 millionth unit is a black and white bi-tone Yaris Hybrid that will go to a French customer. 87% of the total production is being exported to 42 destinations (European region in addition to US, Canada and Puerto Rico). Over the last 15 years more than 1 billion euros has been invested in the plant that has been home to the production of the three generations of Toyota Yaris, an equal number of minor changes, a hybrid version since 2012 and a variant for export to North America since 2013.