Toyota announced on Tuesday that it produced over 1.2 million vehicles and nearly 1.35 million engines and transmissions at its North America manufacturing facilities in 2002.


Toyota, the fourth largest car maker in North America, currently has three vehicle assembly plants in the United States and one in Canada. In 2005, the automaker plans to begin vehicle production at its fifth North American assembly plant, located in Baja California.


Last year, Toyota’s total North American production was 1,205,467 vehicles (1,265,019 including Pontiac Vibe Corolla derivatives built at New United Motor Manufacturing for GM).


Toyota Motor Manufacturing Kentucky last year produced 490,591 vehicles — 317,727 Camry sedans, 76,395 Avalons, and 96,469 Sienna minivans — at Georgetown, Kentucky, which employs about 7,800. The plant also machines and assembles four-cylinder and V6 engines (316,575 and 161,491 respectively for 2002CY).  Beginning this year, Sienna production will move to Toyota Motor Manufacturing, Indiana (TMMI), making way for Camry Solara production at TMMK.


TMMI, located in Princeton, Indiana, completed construction of its East plant in 2002, making way for production of the redesigned Sienna minivan which debuted at the North American International Auto Show last week, and a second Sequoia production line. Production of the new Sienna will begin later this week.


Last year, TMMI produced 186,573 vehicles — 109,022 Tundras and 77,551 Sequoias. With the second plant ramping up to full production in 2003, TMMI’s annual capacity will reach 300,000 vehicles.


Toyota Motor Manufacturing Canada (TMMC), located in Cambridge, Ontario, also plans to increase production capacity, to 250,000 units annually due to increased demand for the new Corolla and Matrix and to accommodate the redesigned Lexus RX 330. This will be the first Lexus built outside of Japan. In 2002, TMMC production reached a record 218,018 total vehicles — 95,030 Corollas, 80,582 Matrixes, and 42,406 Camry Solaras.  Additionally, TMMC assembled 158,269 four-cylinder engines.


NUMMI, which employs approximately 5,000, had a landmark year as it began production of the redesigned Toyota Corolla and the all-new Pontiac Vibe for GM. Additionally, the plant started production of the Toyota Voltz, a right-hand drive Vibe, which is exported for sale in Japan through Toyota dealers. The plant built 310,285 Toyota vehicles including 137,626 Corollas, 8,109 Voltz and 164,550 Tacoma trucks. NUMMI also manufactured 59,552 Pontiac Vibes (not included in the 1,205,467 production figure for Toyota).


Toyota Motor Manufacturing, West Virginia, Inc. (TMMWV) in Buffalo, West Virginia, had another busy year that included a new president, Yutaka Mizuno, and being named by the Harbour Report as the benchmark for four-cylinder engine production.  Total production of automatic transmissions reached 360,957 units in 2002, more than two-and-a-half times the number produced in 2001. TMMWV also machines and assembles four-cylinder and V6 engines. In 2002, production at this facility grew to 352,343 units — 201,273 four-cylinder and 151,070 V6 engines — up from 314,991 units in 2001.


The growth at TMMWV will continue in 2003, with the addition of engine and transmission production for the RX 330. Timing for Lexus engine and transmission production will coincide with the RX 330 vehicle production move to Toyota’s Cambridge, Ontario plant in autumn 2003. Total investment at TMMWV is scheduled to reach $US950 million with these recent announcements.


This year will also see the opening of Toyota’s newest manufacturing facility — a $US220 million V8 engine plant, Toyota Motor Manufacturing, Alabama (TMMAL), in Huntsville. The plant will employ some 350 people and produce 120,000 engines a year for the Tundra pick-up truck manufactured in Princeton.  TMMAL will be the first plant outside of Japan to make V8 engines for the company.


Toyota’s manufacturing growth will continue beyond 2003. The company announced last year plans to build a truck deck plant in Baja California, Mexico, to supply the Tacoma pick-up truck manufactured at NUMMI, beginning in 2004. It was also announced that the new plant, Toyota Motor Manufacturing de Baja California (TMMBC), would begin assembly of 20,000 Tacoma trucks in 2005 to meet increasing demand for the vehicle.


By 2005, Toyota will have capacity to build 1.5 million cars and trucks a year and 1.52 million engines and automatic transmissions in North America and plans to employ some 33,000 people throughout North America at that point.