In the heart of Japan's industrial hub, Toyota is orchestrating a transformation in its manufacturing approach to bridge the gap in battery electric vehicles (EVs). Building on its renowned lean production methods, the world's leading automaker is blending new technologies with time-tested practices to eliminate inefficiencies and streamline costs. During a recent plant tour in central Japan, Toyota unveiled a series of groundbreaking advancements, some revealed to the public for the first time. Among these innovations is a technique for crafting high-gloss bumpers devoid of paint. This process involves meticulously hand-polishing the mold to a mirror-like finish, imparting a stunning sheen to the bumper. In another stride forward, aging machinery, in service for over three decades, has undergone a remarkable transformation. Through the integration of robotics and 3D modeling, these units can now operate around the clock, including nights and weekends, resulting in a threef...

Toyota Motor Corp. is planning to launch electric vehicles (EVs) equipped with all-solid-state batteries in 2027-28. These next-generation batteries are expected to enhance EV range and shorten charging times, positioning Toyota to compete more effectively in the EV market currently dominated by Tesla Inc. Unlike the lithium-ion batteries commonly used in EVs and electrical devices, all-solid-state batteries utilize solid electrolytes instead of liquid ones. This new technology offers numerous benefits, including high-power output, extended range, rapid charging times, and potential for miniaturization. However, there are challenges that need to be addressed, such as the limited lifespan of these batteries and the requirement to mass produce them at a low cost.   Toyota's BEV Factory, an electric vehicle-focused unit, will be responsible for integrating these batteries into its upcoming vehicle models. The company's goal is to develop EVs that can be fully charged in unde...