Where machines cannot reach. This is how Lexus combines craftsmanship and robots in manufacturing

Craftsmanship and technology: Lexus has wanted to go one step further in the development and construction of its new Lexus LC at its plant in Motomachi.

This is how Lexus combines craftsmanship with technology in the production processes of its new models. According to the manufacturer, craftsmanship is a centuries-old tradition in Japan, a country where the most meticulously perfected skills are passed down from generation to generation, creating beautiful objects shaped by expert hands.

“That human touch, the immense attention to detail that only people, unlike technology, can achieve, is the key that makes Lexus and its vehicles something unique.
At the Lexus plant in Motomachi, in the Japanese prefecture of Aichi, the Lexus LC is produced by a team of Takumi master craftsmen and exceptionally talented workers, who apply their vast knowledge to every step of the manufacturing process”.

Thanks to a combination of the most refined craftsmanship and innovative technologies, Motomachi is one of the most sophisticated car factories in the world. With its unmistakable environment of advanced technology, it is no surprise that it was in this pioneering plant that the same engineers and specialists hand-built the iconic Lexus LFA.

https://www.youtube.com/watch?v=6mB2CBdQLzo

Motomachi, a factory where sophistication stands out

Now, the craftsmen are drawing on the skills developed in producing the Lexus LFA, such as developing carbon fiber components and expert hand finishing, to build the Lexus LC to the same level of quality.

From body manufacturing to road testing, the eight Takumi master craftsmen and the rest of the workers each specialize in one specific step of the LC’s production process. Throughout that process, the team demonstrates a practical approach and great rigor and precision. The brand’s DNA embeds the idea that the human skill and spirit are essential to instilling emotion into every Lexus. For this reason, the Motomachi plant has been designed to serve the greatest machine ever created: the human body.

According to the brand itself, “the tools used by the team are in tune with the most advanced technology, designed to achieve craftsmanship at the highest level. In this sense, they have at their disposal tablets with checklists, designed to improve production, which means detecting faults and verifying that no step of the process is skipped. For example, at the end of the body panel and welding processes, which are among the first in the production of an LC, a master craftsman assesses the precision of the chassis alignment with his specially trained eyes; it is an in-depth process involving more than 800 different checks, with the help of electronic sensors to verify the integrity of the welds on the various parts”.

At the Lexus plant, “the execution of the most delicate tasks rests on the harmonious interaction between craftsmanship and technology. Since machines can only detect faults they have been designed to identify, the craftsman can reach a higher degree of precision, because he has the ability to recognize imperfections that may never have been seen before”.

Lighting is another crucial factor in ensuring the best possible quality and allowing the Motomachi craftsmen to detect even the smallest objects. The specially tailored assembly line features a white finish from floor to ceiling, creating an immaculate, perfectly organized work environment that maximizes the team’s concentration. Everything has its place within this well-lit plant, so that, in the unlikely event that an object is out of place, it stands out immediately.

At the end of assembly, the Lexus LC enters a futuristic-looking glass booth, full of light, to undergo a detailed inspection of 700 control points by two of the most skilled craftsmen. Inside the glass booth there are evenly spaced LED bars which, after several rounds of meticulous testing and review, have been placed at 30 cm intervals since, according to the results, that is the best distance for the human eye to detect any defect.

Under the glow of those evenly spaced LED lights, “the craftsmen examine details that customers never even see, such as the precise finish of all exterior and interior surfaces, the color uniformity and the operation of the various components. They devote all five senses to evaluating each vehicle as effectively as possible”.

The final stage before a Lexus reaches the customer is a road test on a special circuit developed by craftsmen trained in high-performance driving.

This last point is further proof of the brand’s conviction in the power of attention to detail that only people can offer: “Lexus trusts the masters’ senses to gather impressions of the vehicle through the steering wheel and make sure all components function safely. It is through that perfect marriage of expert craftsmanship and emotion, between cutting-edge technology and an immaculate work environment, that Lexus delivers incredible experiences and provides some of the finest automobiles ever built”.