Dear NUMMI tour visitor, NUMMI’s tour program, like its assembly line, is designed to run promptly and

efficiently. Unfortunately, those who arrive late miss the first part of the tour. Feel free to read the information below, which is what is being shared during the first part of the tour. If you wish to wait, the tram ride through the plant will begin approximately half an hour after the tour started. In the meantime, if you need to use a restroom, one is available in the Lobby. Be sure to be back here (in the North Admin entrance) at least 5 minutes before the tram ride begins so as not to miss the second part of the tour. We’re sorry for any inconvenience.

Welcome to New United Motor Manufacturing Inc., home of the Toyota Tacoma pickup, the Toyota Corolla sedan, and the Pontiac Vibe. Our 5.3-million-square-foot plant sits on 211 acres. Our 5,700 team members build nearly 400,000 vehicles a year. We operate two shifts –6 a.m. to 2:30 p.m. and 4:30 p.m. to 1 a.m. Maintenance team members are here 24 hours a day, seven days a week. This building opened as a General Motors plant in 1962 and closed its doors 20 years later, laying off 4,000 employees. In 1984 GM and Toyota began the joint venture known as NUMMI. They negotiated with the UAW to pay prevailing U.S. auto worker wages. In exchange, there was a commitment to use the Toyota Production System, which requires more flexibility than traditional labor agreements would have allowed. About 4,900 people here are members of UAW Local 2244 and about 800 are salaried. Team members have excellent benefits, not to mention wages that start at over $17 an hour and go as high as $30. NUMMI pays the entire premium for medical, dental and optical coverage for team members AND their families. We can purchase GM and Toyota vehicles at a great discount. We can also get reimbursed for books and tuition to further our education. We get 16 holidays, including the week between Christmas and New Year’s. And, perhaps most comforting in this uncertain economy, the knowledge that NUMMI has never laid anyone off in the past 20 years. At the same time, however, we must strive to remain competitive in the world auto market.

There are five phases to auto construction: Stamping, Body and Weld, Paint, Plastics, and Assembly:
Phase 1 is Stamping. Each day we use over 1 million pounds of 100% domestic steel. Large coils (about 25,000 pounds each) are unrolled and fed into a blanking press. Like a giant cookie cutter, the press cuts out a twodimensional shape, called a “blank.” The blank goes into a stamping press where dies are used to mold it into a three-dimensional part. The parts from stamping go to Body and Weld. 80% of all welding is automated. On the flexible body line, for example, we have over 50 robots welding together the underbody, the side members the roof and the trunk. We do about five million welds in a typical day. Paint. When the vehicle comes out of Body and Weld it may have dirt, dust and grease on it. It goes through a 12-step cleaning process and then a phosphate bath that roughens the surface to make paint adhere better. That’s followed by a bath that prevents rust and corrosion and adds an electrical charge to help paint bond better. Next, sealer is applied to all seams for waterproofing and noise reduction. Asphalt sheets are applied inside the vehicle to reduce road and engine noise. Then robots prime and paint the vehicle – edges and door jambs are done by hand, and robots finish the job. The vehicle is oven cured at four stages – after cleaning, after sealing, after priming, and after painting. Finally, a team member inspects everything to ensure quality. Total time in the paint process is about 11 hours Plastics is Phase 4. Here we mold bumpers, instrument panels and other plastic parts. Small plastic pellets are melted and injected into a mold. Then the part is cooled and removed – all in less than a minute. Because we

make so many plastic parts – not only for our own vehicles, but also for repair shops and past model years – Plastics is the only department that runs three shifts. The passenger assembly line is where we build the Toyota Corolla, and the Pontiac Vibe – both built on the same line by the same people. Each day at NUMMI we build about 920 cars. The passenger assembly line is about 1.5 miles long, it takes about 6.5 hours to assemble a car and a new car comes off the line every 56 seconds. We build about 650 trucks a day, and the truck line is about a half a mile long, it takes about 3.5 hours to assemble a truck, and every 82 seconds a new truck comes off the assembly line. The Tacoma is made up of a frame, bed and cab. We stamp parts for the cab at NUMMI. Frames are delivered every hour from Stockton and beds come daily from Long Beach. The beds come pre-assembled and pre-painted and are sent to assembly in the proper color sequence to be added to a matching cab. The entire process – from stamping the parts until the completed vehicle comes off the line – is less than 24 hours. Each vehicle built at NUMMI goes through a series of quality inspections in the manufacturing process. Quality Control assigns inspectors to the line to help check quality at the workstation. We have a vehicle test track out back where Quality Control conducts performance checks. Each day they drive randomly selected vehicles on a track that includes a wavy road, rope road, brake test area, and high speed banks. Owner feedback about the quality of NUMMI-built vehicles is very important to us. Quality Assurance’s primary responsibility is to ensure customer satisfaction, so QA monitors overall quality by auditing everything from fit and finish to chassis inspection before vehicles are delivered to GM and Toyota. Following are some Japanese terms and a little bit about the Toyota Production System – the lean manufacturing process that has made NUMMI so successful. Jidoka means building quality in station. A work station is about 18 feet from end to end. If a team member encounters a problem as the vehicle travels through his area, he pulls the Andon cord. This triggers a musical tune that summons help. Everyone who works in assembly has the power to stop the line so problems can be addressed on the spot. The Andon cord is pulled about 1,000 times per shift. 96% of the time the problem is corrected without stopping the line. Muda means waste. Wasted time, energy, motion, space or money are all forms of muda. Kanban is part of our “just –in-time” delivery of parts to the line. Kanban racks hold about 2 hours worth of parts at the line. The racks are filled every hour. Our parts department holds another 2 hours worth of parts. Under roof, we have about 4 hours worth of parts. Out in back we have trailers filled with enough parts to keep our lines running a maximum of two days. Kanban minimizes the number of parts on the line, which means more room and less clutter. Plus it’s less expensive to stock a smaller inventory, there are fewer damaged/lost parts, and problems are discovered sooner. Kaizen means continuous improvement. Anything you can do to make your job quicker, easier, safer, or less costly is a kaizen. The final Japanese term is genchi genbutsu. It means go and see. Please be sure you are in the North Admin entrance 25 minutes after your tour was scheduled to begin so you can join the tram ride through the plant and “go and see” the things you’ve been reading about. You can keep this page or return it to the guard to be used again.