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TURKISH DELIGHT
'Zero defect' quality from a state-of-the-art plant
VERSO is the first imported Corolla model ever to be sold in South Africa, all previous local market models having been produced at Toyota SA's Prospecton plant. The new compact people-mover is made exclusively in Turkey, in a state-of-the-art factory at Adapazari.
Established in 1990 as TOYOTASA, the Turkish manufacturing company, a wholly owned subsidiary of TMC, was renamed Toyota Motor Manufacturing Turkey (TMMT) in 1990. The current facility, built in 1994 on a site covering 82 hectares, has been producing Corolla and Corolla Wagon models for the European market.
The plant was 'apprenticed' to an existing factory, the Japanese Takaoka facility in Toyota City, which was nominated to provide advice and training to the newcomer. 'Rising to the challenge, the Turkish workforce achieved the same level of quality as the mother plant within two years of operation,' says Johannes Thammer, vice-president, Product and Sales Planning, at Toyota Motor Manufacturing Europe. By 2003, TMMT had achieved a zero defect rating in Toyota's international quality audit, making it one of the group's best-per-forming manufacturing facilities.
Human relations manager Vahap Çoymak says the plant's success is largely due to the quality of the workforce, which includes a high proportion of university graduates and technical high school diplomates. Eighty per cent of employees speak only Turkish, while 10 per cent are fluent in English, and seven per cent speak Japanese. The remaining three per cent are conversant in both English and Japanese.
To produce the new Corolla Verso, the plant's annual production capacity has been increased from 100 000 to 150 000 units. The workforce currently numbers just over 3 000, and total investment in the facility amounts to 700 million euros (around R5,5 billion).