Japan – Toyota has held a production ceremony at Motomachi Plant in Toyota City to celebrate what it is calling "the milestone of a new age of vehicles". The OEM has launched its hydrogen fuel cell sedan, the Mirai, which will roll off the factory's production line at the rate of three units per day.
Established in 1959, Motomachi was Toyota's first plant devoted to passenger cars and has produced models such as the Publica, Corona, Cresta, Soarer, Supra, RAV4, and the Lexus LFA supercar. Just over two years since the last LFA rolled off the line, the "small but dedicated facility" will now be home to the Mirai.
The Mirai production processes can be viewed below.
Above: The assembly line for the Mirai is divided into three main sections: trim, chassis/fuel-cell assembly and final assembly. Each section contains subassembly areas for parts installation. This video shows an overview of the production line as well as the parts selection process which takes place close to the assembly line.
Above: Before each Mirai body is brought to the former LFA Works assembly line, it is painted on the mass-production line. The doors are then removed to enable more efficient interior work and prevent damage to these components. This video also shows the installation of the wire harness, dash silencer, brake fluid tank, rear combination lamp, instrument panel, main battery, roof lining and rear bumper.
Above: The Mirai features a carbon fibre reinforced plastic (CFRP) stack frame which is produced in the assembly area at Motomachi. After fuel-cell stack installation, the boost converter, hydrogen tank and tubes are fitted to the vehicle. This video also shows the hydrogen leak test which is performed using helium. Next, the fuel-cell stack and hydrogen tank are installed simultaneously, followed by preparation of the electric motor and the marriage of the air compressor to the fuel-cell stack. Before the chassis assembly is complete, the drive shaft, front axle, inverter, water heating unit, high-voltage cable, front suspension, motor, rear axle, front bumper and wheels are installed.
Above: The final processes are the installation and assembly of the external power supply system, vehicle interior, engine bay, windshield and rear windows. This video also features the final interior trim installations, including the seats, doors, steering wheel and inverter cover. An ignition check is performed before final inspection.
Above: Detailed quality control and inspection are performed using both visual and tactile methods to ensure that the Mirai is defect-free before departing Motomachi.