Following the press preview days at the 2015 Tokyo Auto Show, I had the rare opportunity to watch what just might be the world’s most unique automotive assembly line in action.
Mazda escorted a select collection of international journalists from Tokyo to the company’s headquarters in Hiroshima, home of the automaker’s primary production facilities. The tour included a walk around of the main production line while it was in full operation.
I’ve visited plenty of automobile factories. I’ve watched BMW put cutting edge technology to work outside Munich and driven a brand new Hyundai off the production line in Montgomery, Alabama. I’ve watched Ducati stack up Monsters in Bologna and Harley-Davidson pull V-Twins together in Milwaukee.
The Hiroshima Mazda line is unlike anything I’ve ever seen. The company’s Monotsukuri Innovation systems streamline and organize the Mazda production process so efficiently that the Hiroshima line does what no other manufacturing line can manage.
The standard automotive assembly line makes one specific make and model. The crew might be able to alter paint colors on the line or even add bespoke touches like remote starters or luggage racks. But, it’s the same car at its core.
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On its Monotsukuri line, Mazda can build any car in its line, in any order, in any color, in any configuration. I watched a little red MX-5 move its way down the assembly course, chasing a white CX3 and trailed by a blue CX-9. Some cars were left hand drive, some right hand — most automatic transmission and some manual. That’s unheard of in the world of car building.
Mazda doesn’t allow photos on the factory floor because its technology is obviously top secret, but the Monotsukuri techniques allow this smaller automaker to save on factory space and production costs — guaranteeing it can keep its great looking cars affordable.
