tahara, japan — hidden among the gleaming trappings of a state-of-the-art toyota auto-production plant — the robotic arms and the dust-free rooms — is something that even the ancient samurai of japan would recognize. at the factory, west of tokyo, which makes ls, gs and is lexus models, cameras zipping around on robotic arms take more than 1,000 images of each car to check digitally for imperfections. during a rare tour of the plant thursday, workers demonstrated how they trained for dexterity by turning two golf balls in each hand, and they clawed at rubbery nets to strengthen their fingers. like students rising through the different degrees of judo belts, workers take tests — mostly right on the assembly line — to climb from the lowest grade, which has 1,800 lexus workers, to the second grade, with 600 workers.
they do sit-ups and work out on cycling machines to stay in shape to do the job right, said takahiro iwase, who oversees the tahara plant. “the only way is to build the right mind-set.” except for the lexus rx produced in canada, all lexus models are made in japan, which the company says still offers the best in manufacturing, although worries are growing about quality control amid a surge in recalls. toyota said demand for its latest hybrid lexus models — which include the world’s priciest hybrid at $122,000 — has been stronger than expected. since the may 17 rollout, the company has received 5,300 orders for the ls600h and ls600hl, far above the monthly target for 300 cars.
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