ENGINEER'S DREAM FACTORY - WORLD'S MOST AGILE & FLEXIBLE PRODUCTION SYSTEM BY MAZDA
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- Опубліковано 3 чер 2024
- Automotive Engineer David Chao reveals the world's most agile and flexible production system - essentially an "Engineer's Dream Factory." And no, it's not a Toyota factory... in fact it's the Mazda factory in Japan. David visited the Mazda Hofu plant in Japan in his recent trip, and came to a conclusion that Mazda has the most flexible manufacturing system in the world for a volume manufacturer. Watch the entire video to understand why.
Automotive Press is owned and managed by David Koichi Chao, a global expert in the field of automotive evaluation, consulting, and strategy. David is known around the world as an authentic specialist of Lean Thinking or Toyota Production System. Born and raised in Japan, David has an engineering degree from University of British Columbia and post-graduate education from MIT and Harvard Business School in Boston. - Авто та транспорт
I think Mazda is underrated....
It’s just overpriced otherwise people know how reliable and beautiful it’s.
@@youtubesurfer1533 I think they're reasonably priced for what you get.
Hi David, after 30 years of German cars (last ones were BMW 3 and Audi A4 in total 5 of them), I have choosen a Mazda CX60. I was actively looking for a plug-in hybrid after good experience with BMW 330e. Having a technical background, I have a lot of respect for Japanese perfection. Finally made the decision, and this video was one of the reasons! I have just ordered a CX60 from Mazda. By-the-way my first car was a 1978 Mazda 323, so I am back at the beginning. Thanks for your great videos!
And this is why my wife and I each drive a Mazda, and two of our kids drive Mazda's as well. And we've been driving Mazda's since the 90's.
Gotta love the ingenuity of the production/manufacturing engineers and Mazda's quality control.
David, thanks again for your review of Mazda's production in Japan. As a smaller company with fewer different models and sales volume, Mazda has come up with an ingenious way of being very productive and maintaining excellent quality. I am hoping you will be able to tour Toyota's Japanese plants next year when they open up to visitors.
As an Industrial Engineer who focuses on lean manufacturing Mazda production system amazed me. I think being have to constantly work with small lot sizes made Mazda super flexible. Waiting for my CX-60 by the way :) Amazing video!
Thank you so much!
I just purchased a 2023 CX-5 Sport Design (Canada) for my wife. I have driven many cars in my life including Mercedes, Porsche (Macan GTS $125,000) BMW X5, and others. I am blown away on how well this Mazda drives! The quality of this vehicle for the price is outstanding. I promised myself I would never by a Mazda due to the rust issues they had a while back. I hope the rust problems are solved and the reliability is what people say it is.
I’ve had 4 Mazdas. All of them wonderful. Once I bought a Volvo and went back to Mazda. The same after I bought a Mercedes.
Thanks David for the insight into Mazda...a very underated brand 👍
Mazda never ceases to impress me. For being such a small company, they really know how to play their hand. Thank you for sharing your expertise!
Thank you for sharing with us, David. Mazda makes absolutely awesome and beautiful vehicles.
Thanks for sharing this.. as a former Manufacturing Engineer, and now Design Engineer this insight into how Mazda has increased flexibility by modularization their production lines is really great.. And as a Mazda owner since 2011 (just bought a new 2023 CX-5) I agree that their cars quality is world class.
Thank you for your insight! I agree on Mazda's quality (post 2012) and had a feeling that their factories, operations, engineering, and quality control are step above everyone else. But your factory insight confirms my observations
Thank you for your dedication in making this video. As a common construction worker truck driver guy, I had no concept of what a high tech engineers dream factory would look like. Absolutely amazing!
Thanks for this video David. I absolutely love Mazda too. I hope to visit Japan some day to visit Mazda’s factories. Long live Mazda!
We are in the market for a small crossover and have looked at Mazda and Toyota. I really learned a lot about the company and their products in your recent videos. Despite the fact that I have been a Toyota guy for the past 30 years I think I am going to give Mazda our business this time, the products look a bit more refined for the same money.
I am still rolling my 13 Years old Mazda 6 with 220tkm without problems. ❤😊
Great video, bought a Mazda and I am impressed with the quality
David, I have owned 6 Mazda’s and every one has been excellent. Yet in my experience most consumers in Canada don’t even consider them. At least I can find my Mazda 6 in a parking lot since it stands out.
I found your review to be very informative. I have been driving Mazda for over 20 years and will be getting the CX90 S in Oct. All the points you made about quality, performance and handling I do agree with. Thanks for this review.
Thanks for the tour, I’m very impressed with their system. As someone who has worked in the industry building Toyota truck frames in the past I can appreciate this industry and what’s involved in making it all come together.
love this video! it's like being back in university lecture hall; appreciate this 'educational video.
Our family owns two mazda..2023 cx5 gt and a 2017 cx3 gt...now I know why we love Mazda...
I LOOOVE videos like this! Thank you so much! Mazda is my favorite automaker 😊
Fascinating video, David! Very well done and extremely interesting!
Thanks David for the insight into Mazda...a very underated brand.
I have just ordered my first Mazda.
UK CX60 Homura.
Can't wait!!
David, In the modern context, I have no reason to challenge your assertion that these Mazda plants are the most flexible auto factories in the world. In the historic context, we had many factories producing 4-6 body styles of the same model with 4 transmission choices, 6 different engines, 6 interior seating and upholstery choices and 16 colour options. Many of those old factories actually produced more than one model. More than anything, the flexible production shown in this video really reinforces the message of how standardized auto production has become over the decades.
In every factory in the world, the multiple 4 to 6 body styles are actually based on the same platform or similar chassis. High volume car companies do not produce completely different models (with different platforms) on the same line. If you go to all of the Toyota factories (I've been to 95% of them), only similar models are produced on the same line. After seeing more than 200 automotive factories around the world, I can still say that the Mazda model is unique and more flexible than others.
@@AutomotivePress Absolutely! That is why I did NOT challenge your assertion. 😁
@@rightlanehog3151 You can challenge me anytime Mike!
@@AutomotivePress Good, I will keep that in mind.
I was fortunate to have visited Volvo’s factory in Gothenburg, Sweden and was very impressed with their facility and methodology in production. Very high quality and precision, as well as the well being of their employees.
Wow great video David, very awesome to take a look in the factory and also very educational. Keep up the amazing work. 👍🏼
Fantastic video. Thanks for sharing. Pls do make more videos that provides insights into the production of vehicles. Interesting stuff!
David, thank you for another fantastic video! I look forward to the next one!
I already loved Mazdas but this is a very cool insight into how they are built.
This is highly interesting content. I also very much enjoyed the Toyota museum video.
Thank you for posting this. Can’t wait for more.
Very impressive David. Thank you for sharing!
Great video David! Keep them coming.. would love to see you potentially view more factories around the world and hear your thoughts on the comparison with Japanese factories
I love the way they design these cars, both interior and exterior is well built. In short i greatly appreciate that Mazda exists!! and the content you making.
Thanks David, I have had a few Mazdas the recent years, I own a 2000 Mazda Millenia S now that used to be my dads. I also have a 2020 4Runner.
Great video thank for insider look into Mazda.
Thanks for the educational video. I am so glad I watched this because I thought that was gonna be David's favorite Tahara again for sure.
I presently own 2 Mada vehicles and have owned six in all. Love the vehicles and enjoyed seeing this video on the factory and build quality.
David, your reviews are always informative. I love them all. I love to watch Subaru production and their quality if you have a chance. Thanks
thank you David for all the info.
Family owns 3 ,2017 CX5s. Besides the infotainment system ,the small suvs are perfect. I personally change the oil every 5k miles and its soooo easy to do this.
Perfect Content as per usual!!!!
I wish the Tundra was made in Japan. Only 15 percent of Tundra are made in Japan.
Thanks for your illustrations. I own 2 different CX5 in the last 10 years. I'll buy another in a few years if they still make the CX5 perhaps with a hybrid design, provided it's still affordable to me. Designers are very practical with almost no haptic touch sensitive buttons. Did not follow the other premium brands. Great design leadership. Hope they stay doing what they're doing. I left Honda after being their fan for 25 years. Loved my Integra GSR and Civic Si. But I switched to Mazda 10 years ago and never looked back.
J adore mazda voir la production des vehicules est impressionant
A lot of info packed into a short time. Pretty fun.
👍👍👍. Very interesting and informative video. Thanks,
I dig your videos Toyota of indiana did Seqouia and highlander plus the minivan surprised me as the sequoia is frame on. Never owned a mazda but have had 8 toyotas. Very amazing thank you... Now if I could get a RX7 now that I have money...
Great job 👍 learn alot from video.
Excellent! Production Engineering for the 21st Century in Mazda Japan. Toyota, come on show them how do it more efficiently!
Great videos I saw you on the car care channel. Now I’m hooked on your channel considering a Mazda, CX five Do you consider reliability of Mazda engine just as good as Toyota engine thank you for your great videos
Thank you for the informative video, very interesting. I myself drive a 2021 Mazda 3 e-Skyactiv X MT, it truly is a product made by great engineers and technicians.
Again, thank you very much for the factory tour!
Now, only if Mazda could 'reengineer' their North America dealerships. Worst part about Mazda experience is their dealerships that rip you off everywhere, trying to sell you not needed services, have bad service shops, not knowing the proper maintenance plan, price 2x-3x parts (yes, dealerships price gauge parts!) compared to online OEM parts retail.... I always buy parts online myself, then either try to swap them myself or go to a trusted mechanic who would do the labor using my parts.... Shouldn't be that way, but surely is
That´s really an impressive video and indeed state-of-the-art production! Very good video!
So will have the Hofu plant as the only plant from Mazda this flexible produvtion system? Or will Mazda transfer it to other plants in the near future?
my mazda3 was built in japan and i love it looks and runs very well they do a great job and i think they are the best cars made today better then any usa cars made now a days or any car in the world worth every cent i paided
Very impressive presentation... well done David.
Glad you liked it!
That's awesome. Conceptually, it's not a wild concept. But that level of implemented AGV coordination is extremely impressive. I believe Amazon uses them for item handling. But I don't believe they have to interact with a moving line. And if a box of stuff gets dumped, it's not a big deal. Collisions with a chassis would be bad stuff.
Very intriguing!
I am so glad Mazda gave Ford the boot years ago because their quality was poor during that time. I would have never considered a Mazda during that time. Now that Toyota has merged with them I'd would definitely feel very comfy in their quality. Thanks David for valuable product information 👍
It was actually the other way around, Ford continued to divest it self from Mazda until they had nothing left of them.
Mazda has not merged with Toyota, each own 5% of each other that is all. The MTM plant in USA is that 5% venture, a $2billion all new plant , first car off MTM is CX-50 for North America ONLY.
Very impressive! I wanted to visit the Toyota plant, but unfortunately I was not able. I have a relative that works for Toyota in the design area. Maybe some day!
I love my 2016 cx3!
I own a 2023 CX5 & I’m impressed by its overall quality, except for its exterior paint which is less resilient to sustaining chips & swirls after long journeys & car washes, compared to other cars I’ve driven over a decade. I hope /@mazda looks into this issue.
Mixed body style production is quite impressive. It's like a restaurant having a 10-stage pipeline for making dinners and making, steak and eggs, turkey and stuffing, and fried chicken and mashed potatoes on the same line. Are there any books that describe the Mazda Production System?
Damn that cx60 is a beauty wish we got that here in the states I know the 70 and 90’s are coming but I prefer the 60 size as a replacement for the cx5.
That was great. Wanna buy Mazda!
Hi David! I want to buy Mazda cx 30 g150 skyactive for EU market. Shoud i be worry about cylinder deactivation? I heard a lot of bad experiances for CD .
I just bought a 23 CX5 ,great video
I sure hope they bring back the RX One day
Nice video!
Hi David. Appreciate your report on Mazda's automobile production, Mazda's emphasis on multiple-unrelated-model production on the same assembly line, and Mazda's flexible production vs Toyota's mass production (similar vehicles on one assembly line). Does this mean Mazda production method has a higher cost than Toyota production method? I watched a documentary on Porsche Zuppenhausen production line and I think Porsche is also using AGVs for multiple vehicle model assembly? Is that true? Or is Porsche making similar models on one assembly line? I just saw another Mazda production documentary (2016-2019). It seems that Mazda is casting their own engines in the same plant where they are completing final automobile assembly. Is this true? Is Mazda casting specific engine blocks in the same plant where they are completing final assembly of the entire vehicle?
Hi David, which Mazda models are built in Japan?
love japan, for cars and bikes!
Great video. But are the model on sale in North America made in Japan?
Some. Easy to see by checking the VIN. CX-5, MX-5, and my Mazda3 hatchback are currently Japan made. CX-50 are made at MTM in Alabama. Some CX-30 and Mazda3 are made in Mexico. All other Mazda factories besides the Japan, mexico, and Alabama plants supply vehicles to other markets.
Love Mazda
David, how does the joint venture factory between Toyota and Mazda in the United States work? Does Toyota want to optimize its production management technology?
That factory looks like a museum.
I wish we got an awd mazda 6 wagon here in US
Their hardwork is paying off. They even make SUVs fun to drive for what its worth. The one compromise you make with a mazda is car size if it is even a compromise for you.
Wow, thanks David. Plus, I think Mazda makes proven powertrains.
How is the quality of production in the Huntsville Alabama factory USA? Should! I make sure I buy a Mazda made in Japan or American made just as good?
I love Mazda cx90 cx50
Mazda is best car company in world they have proven time and time again they are second non
David @AutomotivePress do you think Mazda will carry over their interoperability assembly process to the shared with Toyota plant in Huntsville? Would the same production/assembly line be able to make a CX50 and a Corolla Cross utilizing the AGVs?
The Mazda Toyota joint venture plant doesn't use those flexible AGVs and the Corolla/CX-50 lines are completely separated.
@@AutomotivePress Thank you! Would love to see you showing that plant too - big difference between the regular conveyor-belt assembly and th AGVs
Mazda can be the Porsche of the JDMs with this. This flexibility should allow them to explore customizable options not unlike the 911. I hope they can leverage this factory flexibility by offering an incredible options list to the customer and really differentiate themselves.
Shout it from on high. Mazda builds great cars
Where are the CX-90's made?
Now if Mazda could build a vehicle that I was interested in like a small pickup.
It could easily be done but they have no interest.
Imagine what Henry Ford would think if he saw this!
my next vehicle will be a Mazda. Should include a device to protect Cat from being stolen....
Have you ever seen a tank powertrain and what it takes to remove it?
Why aren’t cars made like that?
Wouldn’t a powertrain that takes minutes to R&R be cheaper to manufacture and in the long term warranty game be cheaper to support?
It would be interesting to know how the costs of this vs. traditional line compare, taking into account the flexibility of switching models to meet demand. I think that if they design a decent full EV (and the MX-30 sucked, sorry) they will be extremely popular. If they can be assembled in the USA and get the tax credit.
Read Hyundai production systems. They pioneered this flexible system while maintaining Toyota's error proof standard
Mazda has been capture by Toyota reputation for many years and it just need better after sales service.
I wish Mazda would fix my 2021 CX-5 Turbo from using oil like crazy!
They're able to produce what they do because of the nursery rhymes playing in the background. 😆
I thought I was imagining it but I guess I really did hear "London Bridge is Falling Down". 🙂
Keep in mind though that, Mazda has no heavy duty vehicles like Toyota’s Land Cruiser, Prado, Lexus GX, LX, Sequoia, Tundra and 4Runner. Most Mazda’s are same platform with a minimal difference, size.
I hated my 2005 mazda 3. Great handling but the body rusted so quickly, the AC was very weak and parts were expensive. I currently have a 2011 mazda 2. The AC works great. Handling is great. Despite taking good care of it. It started breaking down in 2021 its like every 3-4 months something breaks and parts are very expensive. Even if you replace it, only the dealer could turn off the MIL.
My wife now hates Mazda and wants a Toyota only for our next car.
Matsuda.
You said Toyota and Mazda honor Japanese production ways. Why not Honda, curious.
Yes Honda does follow similar principles, but most of the Honda products sold in North America are not built in Japan - and therefore it's not quite the same level of standard as those built in Japan
@@AutomotivePress thank you for your response. I appreciate your videos and comments.
Notice how Toyota does not allow you to see their paint process. They are very secretive about that. Both in Japan and the U.S.A..
I have always been a Mazda fan. I've owned (2 Mazda Miata) in NA and NC. I also owned (2) Mazda RX-7. I wish Mazda would bring back a version of the RX-7. The RX-8 was total garbage and it was an insult to the RX-7.
Mazda uses the same engine in the three all the way up to the five and maybe even the new nine. Why can't they put that in their Miata?
Automation is interesting tech.
One day there will be no people working the assembly lines with only robots manufacturing car robots (autonomous cars) that when fully assembled and rolling down the street finally get to see people in the back seats. And no traffic police nor police cars … because what robocars will break traffic rules?
If they find a way to stop them rust it could make a change! It is a joke with so much technology with metals, that you can pick up a chair, sit by Mazda and watch it rust. Common, people arw giving money for this car. A friend of mine had an Audi 80 15 years old. Not a spot of rust.