New engine plant replaces one built in 1978

New engine plant replaces one built in 1978

Toyota Australia has opened a new engine plant, claiming to be the first Australian automaker to produce both petrol and hybrid engines.

The factory is at the car making site in Altona, west of Melbourne, and will make around 108,000 I4 2.5 litre engines a year for the locally manufactured Camry and its hybrid variant. Engines will also be exported to Thailand and Malaysia where Camrys are assembled.

Toyota Australia president and CEO Max Yasuda said: "We are now one of only four countries in the world to produce the AR four cylinder engine and are the first Australian car manufacturer to produce petrol-electric hybrid engines."

Yasuda said the unveiling demonstrated the efforts Toyota was taking to transform its operations to ensure local car manufacturing can maintain its presence in a highly competitive marketplace.

"I am a true believer in local car making. We are working to create a new, stronger business that gives us a competitive advantage that is sustainable and profitable for the future. Building a new engine plant in Australia is at the heart of our manufacturing strategy.

"The new engine plant is a significant milestone. It enables us to maintain our workforce and further develop our technologies, skills and products so we can continue building engines and cars in Australia for many years to come."

Along with support from the Victorian state gvernment, the federal government contributed A$63m to the engine plant from its Green Car Innovation Fund.

"An ongoing partnership between local car makers, the government and suppliers is fundamental for ensuring Australian industry can compete," Yasuda said.

The engine plant replaces the original factory built in 1978 which was Toyota's first engine manufacturing plant outside Japan. Toyota had previously sourced some engines from GM Holden to meet local content rules and imported others from Japan.

The new plant starts full production on 14 January building around 450 engines a day.

Toyota, originally represented by separate independent importers for cars and light commercials, began Tiara assembly in Australia in 1963 and follwed that up with the Corolla in '66. Initially, cars were assembled by contractor Australian Motor Industries (AMI).

Toyota Australia's first export model was the Corona wagon to New Zealand in the mid-1980s. In August 2012 it reached 1m export sales, making it the first Australian manufacturer to do so. Later this month, Toyota will assemble its three millionth vehicle.

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Toyota Australia has today officially opened its new state of the art engine plant, making it the first Australian car manufacturer to produce both petrol and hybrid engines. 


Located in Altona, west of Melbourne, the plant will produce approximately 108,000 four cylinder 2.5 litre engines per year for its locally built Camry and Camry Hybrid sedans. The new, more fuel efficient engines will also be exported to Thailand and Malaysia.

The event was attended by the Australian Prime Minister, the Hon. Julia Gillard; Victorian Premier, the Hon. Ted Baillieu; Federal Minister for Industry and Innovation, the Hon. Greg Combet AM; Victorian Minister for Manufacturing, Exports and Trade, the Hon. Richard Dalla-Riva; Mr Seiichi Sudo, Senior Managing Officer, Toyota Motor Corporation; and His Excellency, Mr Yoshitaka Akimoto, Ambassador of Japan.

Toyota Australia President and CEO, Mr Max Yasuda said the official opening was a proud day for the Australian car industry and testament to the company's team members who helped secure the new engine plant investment.

"This is a great day for Toyota Australia. The official opening of the new engine plant is part of our overall mission to transform our operations and build a more sustainable business," Mr Yasuda said.

"We are now one of only four countries in the world to produce the AR four cylinder engine and are the first Australian car manufacturer to produce petrol-electric hybrid engines."

Mr Yasuda said the unveiling demonstrated the efforts Toyota was taking to transform its operations to ensure local car manufacturing can maintain its presence in a highly competitive marketplace.

"I am a true believer in local car making. We are working to create a new, stronger business that gives us a competitive advantage that is sustainable and profitable for the future. Building a new engine plant in Australia is at the heart of our manufacturing strategy.

"The new engine plant is a significant milestone for Toyota Australia. It enables us to maintain our workforce and further develop our technologies, skills and products so we can continue building engines and cars in Australia for many years to come."

Mr Yasuda praised the strong desire of both the Federal and State Governments to see more advanced car making technologies introduced to Australia. Along with support from the Victorian Government, the Federal Government contributed $63 million to the commissioning of the new engine plant from its Green Car Innovation Fund.

"An ongoing partnership between local car makers, the government and suppliers is fundamental for ensuring Australian industry can compete," Mr Yasuda said.

The new 2.5 litre engine boasts significant improvements in fuel efficiency and greater power than the previous 2.4 litre engine. In the current generation Camry this has contributed to an 11 per cent reduction in fuel consumption and a 13 per cent reduction for the Camry Hybrid.

The engine plant has been in development since October 2011. It replaces the original engine plant built in 1978, which was Toyota's first engine manufacturing plant built outside Japan. The plant will go into full production from 14 January 2013 and produce approximately 450 engines per day.

Toyota Australia has been building cars in Australia for almost 50 years. In August 2012 it achieved one million exports sales, making it the first Australian manufacturer to do so. Later this month Toyota will also build its three millionth locally built vehicle.

...ends/71868

For further information please contact:

Beck Angel, 03 9647 4250 or 0421 271 279, beck.angel@toyota.com.au
Glenn Campbell, 03 9647 4557 or 0417 381 692, glenn.campbell@toyota.com.au



ENGINE PLANT FACTS

ITEM

DESCRIPTION

Building size:

•  21,000 metres square.

Product basic:

•  Four-cylinder engines.
•  Machining of local and imported components.
•  Aluminium castings.

Variation:

•  Camry 2.5 engine, seven variations, auto and manual.
•  Approximately 85 per cent petrol engines and 15 per cent hybrid engines.

Raw material:

•  Cast iron and steel components from local vendors and Japan .
•  Aluminium casting from TMCA casting department.

Shift operation:

•  Two production shifts.

Basic process:

•  Casting and machining - cylinder head, cylinder block.
•  Machining - con rod, crankshaft, camshaft, camshaft housing
•  Engine assembly.

Special process:

•  All completed engines tested in test area.

Machines:

•  453 machines in casting area, machining and assembly.

Production:

•  108,000 engines per year, 9000 per month and 450 per day
(Full production from 14 January 2013).

Number of processes:

•  87 per shift.

Export countries

•  Malaysia and Thailand from Jan 2013. Engines to be exported represent approximately 15 per cent of all those produced at Altona (approx. 16,200).

Engine plant investment

•  Total investment is $330 million.

•  Includes support from the Victorian Government and $63 million from the Federal Government.






ENGINE SPECIFICATIONS

ENGINE

Type

Petrol

2.5 litres; 4 cylinders, in-line type; 2AR-FE

Hybrid

2.5 litres; 4 cylinders, in-line type; 2AR-FXE

Capacity

2494cm3

Bore x stroke

90.0 x 98.0mm

Compression ratio

Petrol

10.4:1

Hybrid

12.5:1

Power

Petrol (Camry Altise)

133kW @ 6000rpm

Petrol (Camry Atara)

135kW @ 6000rpm

Hybrid (Camry Hybrid)

151kW combined hybrid power output

Torque

Petrol (Camry Altise)

231Nm @ 4100rpm

Petrol (Camry Atara)

235Nm @ 4100rpm

Hybrid (Camry Hybrid)

Petrol engine - 213Nm @ 4500rpm

Fuel System

Multi-point EFI into intake port

Min fuel octane rating

91 RON

Australian emissions

EURO IV

PERFORMANCE

Fuel economy (litres/100km)#

Petrol

7.8

Hybrid

5.2

CO2 emissions (g/km)#

Petrol

183

Hybrid

121

# Fuel consumption and emissions will vary depending on driving conditions/style, vehicle conditions and options/accessories. Source of fuel consumption data: ADR 81/02 combined cycle.


 



TOYOTA AUSTRALIA FACTS

ITEM

DESCRIPTION

History

•  1963 - Toyota Australia commenced building cars in Victoria.
•  1978 - Toyota Australia 's first engine plant opens.
•  2010 - Toyota Australia announces plans to build a new engine plant.
•  2011 (October) - Work commenced on the new engine plant.
•  2012 (July) - Trial period commences at the engine plant.
•  2012 (December) - Official opening of the new engine plant.

Total engine production volume (by year)

•  2011 - 52,652 4-cylinder engines.
•  2010 - 88,799 4-cylinder engines.
•  2009 - 73,284 4-cylinder engines.
•  2008 - 113,513 4-cylinder engines.
•  2007 - 112,446 4-cylinder engines.

Total engine production volume (accumulative)

•  1.97 million engines.

Locally manufactured vehicles

•  Past - Tiara, Crown, Corolla, Apollo, Nova and Avalon.
•  Current - Camry, Camry Hybrid and Aurion.

Total vehicle production volume (by year)

•  2012 - on track to produce in excess of 95,000 vehicles.
•  2011 - 93,618 vehicles.
•  2010 - 119,455 vehicles.
•  2009 - 96,817 vehicles.
•  2008 - 141,467 vehicles.
•  2007 - 149,931 vehicles (peak).

Total vehicle production volume (accumulative)

•  Just over three million vehicles (made for local and export markets).

Exports

•  Engine export markets - Thailand and Malaysia from January 2013.
•  Vehicle export markets - New Zealand . South Pacific Islands , Bahrain , Kuwait , Oman , Qatar , Saudi Arabia , United Arab Emirates and Yemen.
•  59,943 vehicle exports in 2011.
•  More than one million vehicle exports in total.

Employees

•  Engine plant only - 277 employees.
•  Total manufacturing - 2575 employees.
•  Total Toyota Australia - 4162 employees.

2011 achievements

•  Toyota was the best-selling automotive brand in Australia in 2011, selling 181,624 vehicles.
•  It was the ninth year in a row that Toyota was Australia 's most popular automotive brand.
•  Toyota was the only manufacturer with three vehicles among the top 10 sellers - HiLux, Corolla and Camry.
•  Camry was Australia 's top-selling mid-size car for the 18th year in a row - an unbroken run that began in 1994.

 

Original source: Toyota Australia