Talk about explosive sales.

http://news.moneycentral.msn.com/pro...628&ID=7100185

Lexus Cultivates Elite Work Force

TAHARA, Japan (AP) - Hidden among the gleaming trappings of a state-of-the-art Toyota auto production plant -- the robotic arms and the dust free rooms -- is something that even the ancient samurai of Japan would recognize.

It's a "dojo" -- rooms housing a training program where workers are taught to gauge proper bolt-tightening by the buzz of an electric screwdriver, and how to pat parts into the car with the right touch, like an acupuncturist at work.

Toyota Motor Corp. says that its "master craftsmen" at the Tahara plant, the 2,700 veteran workers whose eyes are sharp enough to catch minuscule errors even robots and computers miss, are the secret behind its vaunted quality.

At the factory, west of Tokyo, which makes LS, GS and IS Lexus models, cameras zipping around on robotic arms take more than 1,000 images of each car to check digitally for imperfections. Then corners and curves are examined by the human eye for more fine-tuning.

Anyone who enters the room where the engines are built is hit with a blast of air to make sure not a speck of dust gets into the parts during production.

The alignment of a car when parts are put together has been perfected to such a degree that when a Lexus driver lets go of the steering wheel at 62 mph for about 100 yards, the car will veer just 10 inches, rather than the usual 30 inches, according to Toyota.

During a rare tour of the plant Thursday, workers demonstrated how they trained for dexterity by turning two golf ***** in each hand, and they clawed at rubbery nets to strengthen their fingers.

In another exercise, they lined up dozens of token-like pieces of barely discernible shades to train their eyes to distinguish color.

Like adepts rising through the different degrees of judo belts, workers take tests -- mostly right on the assembly line -- to climb from the lowest grade, which has 1,800 Lexus workers, to second grade with 600 workers.

The top grade boasts only 300 workers. They are all tested every four months on production techniques to make sure they haven't slacked off.

At the dojo, employees also get a dose of what's called "mind training," designed to nurture sensibilities through classes about the Lexus concept.

They do sit-ups and work out on cycling machines to stay in shape to do the job right, said Takahiro Iwase, who heads the Tahara plant.

The root of quality production is to maintain human virtues, he said.

"Our conclusion was that there can be no how-to manual to master the Lexus production method," Iwase said. "The only way is to build the right mind-set."

A diagram for the ideal female worker, hanging on the plant's wall, called for neat attire, including no heavy makeup. Big signs hung from the ceiling with bold letters proclaiming: "Good products; good thoughts."

Except for the Lexus RX produced in Canada, all Lexus models are made in Japan, which the company says still offers the best in manufacturing, although worries are growing about quality control amid a surge in recalls.

Lexus consistently ranks high in consumer satisfaction surveys and was second overall after Porsche in this year's annual J.D. Power and Associates initial quality rankings, which measures satisfaction after three months of ownership.

Toyota said demand for its latest hybrid Lexus models -- which include the world's priciest hybrid at 15 million yen ($122,000) -- has been stronger than expected. The models are planned for overseas sales later this year.

Since the May 17 rollout, the company has received 5,300 orders for the LS600h and LS600hL, far above the monthly target for 300 vehicles.

Toyota Senior Managing Director Shoji Ikawa said production quality, such as eliminating gaps between parts to a sliver, attained with the first-generation Lexus is now commonplace in regular cars such as the Corolla.

"We will always be trying to attain the next level," he said. "We abide by the philosophy of no compromise, and making a point to get to the bottom of any problems that may arise."

 

Incredible, incredible. Lexus has taken it to another level with the most techologically advanced car(s) in the world.

Hybrids. The halo this car provides will be TREMENDOUS. A TRUE flagship.

Kudos, their management is top freaking notch

 

Damn, that sale figure # is unreal... awesome

 

So much for Lexus being a flop in Japan. Amazing it only took one single vehicle to drive sales beyond expectation.

 

Congrats. Keep it up

 

The LS has been a major success and just what Lexus Japan needed, the LS 460 itself had 12,000 preorders in the first month which blew past expectations as well. The LS 600h/600hL is a lot more expensive.

 

Very interesting article. I am always proud we have the ever improving LS as our flagship.

 

That is a phenomenal number of cars in the first 40 days. Isn't that the whole allocation number of LS600hL for the U.S. for the first year?

 

I don't think supply can keep up with demand. Lexus said LS 600s were special order ONLY and only 5% of LS sales.

Lexus is on pace to sell around 38,000 LSs in the USA this year, maybe 50,000 worldwide?
This is over 10% of LS allocation.

Those are just my estimates. A huge feat.

People DO want a 100,000 Lexus. Lexus has PROVEN it makes a product people want, no matter the price.

 

I would have never doubted this, even if they didn't offer hybrids. However, I think they are definately headed in the right direction. Luxury, power, environmental responsibility, and damn good fuel economy.

 

Good job by Lexus & hybrids are always big in Japan too.

 

holy, this is insane!!!!!!!! keep in mind this is the most expensive car in the lexus lineup (and it itself is expensive to begin with). just big wow....

i hope they can keep up with the demand especially since a lot of stuff on the car are hand made. i just wish they didn't cap the number of cars sold here in the US

 

God, can you imagine UAW workers being forced to do workout regimens? Can you imagine the EEOC allowing posters of "ideal" female workers in American plants? Can you even imagine a testing plan for higher-grade workers where they actually have to requalify every few months rather than being "tenured" for life? No wonder Toyota's quality is ever-increasing...

 

I would love to see a video of the Lexus employees doing all these insane regiments. Discovery Channel go knock on Toyota / Lexus door hehe

 

I think it's much more, I think allocation for the US in the first year is only about 2,000 ?