TMMTX operations will ramp up in steps. Beginning back in September, the plant began pilot versions of the truck. This phase was designed to make certain

- that all the production equipment works as it was designed to work
- that all manufacturing processes all work as they should
- all team members are properly trained
- and that all the parts fit together correctly on the truck.

The TMMTX factory floor features a blend of automation and manpower. In the welding and painting areas of the plant, robots do much of the work. Nearly 400 handle painting and welding, making those areas about 90-percent automated.

Even where manpower is primarily used, a variety of "assist devices" help assembly workers lift and move heavy, bulky items such as seats and doors. Using this creative combination of muscle and machine, it takes about 24 hours going from raw, coiled steel to finished, painted, rolling and running state-of-the-art pickup.


ENVIRONMENTALLY-ADVANCED

In keeping with its state-of-the-art technology and processes, Toyota's newest production facility will be the company's most environmentally-advanced to date. For instance, TMMTX has prioritized the reduction of paint booth emissions by using only cartridge-based paint systems. The advantage is that it eliminates the need to purge paint lines when a color change is made. The primer paint booth uses a water-born paint system, a first for Toyota in North America and further protecting the environment.

Water, in fact, is an important consideration in this area of Texas, and TMMTX employs a number of water conservation measures. The plant was designed to consume as little as possible. TMMTX buys recycled water from the San Antonio Water System for 100 percent of its processes. The only fresh water used at the plant is for the kitchen and restrooms.

In addition to conserving resources and preventing emissions, the San Antonio plant reduces waste in a number of ways. It operates as a zero-landfill facility, meaning no waste will be taken to a landfill. The plant will recycle extensively.

For instance, scrap steel will return to the steel mill, scrap plastic will be shredded and returned to a pellet manufacturer. Even the amount of packaging of new parts - packaging that might ordinarily be thrown away - has been minimized. Substituting wooden pallets with plastic will also make a difference. Wood breaks up and wears out, then must be disposed of in a landfill, while plastic can be used over and over again for a much longer period of time.

"TMMTX is a not only a brand-new plant for a brand-new truck, it's Toyota's opportunity for long-term growth in the full-size pickup segment and the community of San Antonio," said Esmond.

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