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Toyota Motor Manufacturing Indiana
Toyota Motor Manufacturing Indiana
Toyota Motor Manufacturing Indiana
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Toyota Motor Manufacturing Indiana (TMMI) is an automobile manufacturing plant complex located in Gibson County, Indiana, United States, nearly halfway between Princeton and Fort Branch, and mostly in Union Township. It is a subsidiary of Toyota Motor North America, itself a subsidiary of Toyota Motor Corporation of Japan. With over 7,000 employees, TMMI is the largest employer in the Evansville Area.

Key Information

History

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Toyota Motor Manufacturing Indiana was built in May 1996[2] to begin production of a full-size pickup truck solely for the North American market. TMMI began production of the Tundra in 1999 for the 2000 model year, and Sequoia production began a year later for 2001. Both the Tundra and the Sequoia were new to the market and have only been sold in North America; the Tundra replaced the Toyota T100 in the US market.

In 2003, production of the Sienna minivan shifted to TMMI for the release of its redesigned 2004 model, while Toyota Motor Manufacturing Kentucky produced the Solara in place of the Sienna.

On July 10, 2008, Toyota announced that they would consolidate Tundra production at Toyota Motor Manufacturing Texas in San Antonio after 2008. Owing to the large unsold supply of Tundras and Sequoias, production of both Tundras and Sequoias would be suspended. Toyota also announced that production of the Highlander would be shifted to TMMI and would start in 2009. Production of the Sequoia later resumed, although at a reduced output.

Layout

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The roughly 4.5 million square foot factory is split into two different plants. The original factory, "West Plant," originally built to produce Tundras, began producing Highlanders then Sequoias but now produces Highlanders, Grand Highlanders, and in September 2023 will begin producing the Lexus TX. TMMI later expanded to add "East Plant" which produces Siennas, and now produces the bulk of Highlander orders as well. Both plants have joined weld, stamping, and plastic production sections. East Plant also started producing Highlanders as of 2016. Both plants have undergone large expansions to support the high domestic and worldwide demands for the Highlander, and Grand Highlander.

TMMI is the sole source of Highlanders for all markets worldwide except China. Chinese-market Highlanders are made in China exclusively for the Chinese market.

Present automobiles produced

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Past automobiles produced

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See also

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References

[edit]
Revisions and contributorsEdit on WikipediaRead on Wikipedia

Toyota Motor Manufacturing Indiana

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Toyota Motor Manufacturing Indiana (TMMI) is a major automotive assembly plant located in , owned and operated by , Inc. Groundbreaking occurred in 1996, with vehicle production beginning in 1998, making it one of 's key U.S. facilities focused on building SUVs, crossovers, and minivans using advanced manufacturing technologies. The plant currently produces models such as the , Grand Highlander, Highlander Hybrid, Hybrid, and the , and it marked the milestone of its 1 millionth in June 2025 with a 2025 Platinum. Since its inception, TMMI has grown significantly, with Toyota investing a total of $8 billion in the facility to enhance production capabilities and introduce innovative processes. The employs more than 7,600 team members, supporting the local economy as one of the largest employers in southwestern , and recent expansions—including a $1.4 billion announced in 2024 to add up to 340 high-quality jobs—have further boosted its capacity for hybrid and electrified vehicle assembly. In 2024 alone, TMMI produced 328,136 vehicles, contributing to a cumulative total exceeding 6 million units built at the site. TMMI incorporates cutting-edge technologies, including robotic systems for and , exoskeletons to assist workers with ergonomic tasks, and Toyota's New Global Architecture platform for efficient vehicle design. Beyond production, the facility emphasizes , with nearly 1,000 employees over 10,000 hours in and Toyota donating more than $54 million to local initiatives since its opening. These efforts underscore TMMI's role in sustainable manufacturing and .

Overview

Location and Facilities

Toyota Motor Manufacturing Indiana (TMMI) is situated in , near the city of Princeton, approximately 25 miles north of Evansville in southwestern . This location positions the plant strategically within a region that facilitates efficient distribution across the Midwest and beyond. The facility occupies 1,160 acres of land, with a total building footprint of approximately 4.5 million square feet spread across two primary structures: the West Plant and the East Plant. These plants house essential , including body shops for and structural assembly, paint shops for vehicle finishing, stamping operations for forming, and assembly lines for final vehicle integration. TMMI benefits from excellent accessibility via major transportation routes, such as , U.S. Highway 41, and , which intersect in Gibson County and connect to broader interstate networks. Its proximity to over 80 suppliers throughout and key logistics hubs, including the and ports, supports streamlined operations. As one of 's primary production sites in , TMMI plays a vital role in the company's regional strategy.

Ownership and Operations

(TMMI) operates as a wholly owned subsidiary of (TMNA), reflecting 's broader strategy to localize vehicle production within the to enhance efficiency and market responsiveness. This structure positions TMMI as a key component of TMNA's network, enabling seamless coordination with other North American facilities for component sourcing and assembly processes. As of 2025, TMMI is led by President Jason Puckett, who also serves as Group Vice President of Manufacturing Region 2 within TMNA, overseeing operations that integrate the Indiana plant with facilities in and . This leadership ensures alignment with TMNA's overarching goals for and operational standardization across the region. The plant maintains an operational capacity that supported the assembly of 328,136 vehicles in , contributing to a cumulative total exceeding 6 million vehicles produced since its inception. These figures underscore TMMI's role in meeting North American demand while adhering to efficiency targets set by TMNA. TMMI employs the (TPS), incorporating core principles such as Just-in-Time inventory management to minimize waste and ensure timely material flow, and Jidoka, which emphasizes with human oversight to detect and address defects immediately. These elements are adapted to the facility's specific workflows, supporting high-volume production of diverse vehicle lines while maintaining rigorous quality standards integral to Toyota's global operations.

History

Establishment and Early Development

Toyota Motor Corporation announced plans in December 1995 to build its first full-scale truck manufacturing plant in the United States, selecting a site in Princeton, , for what would become Toyota Motor Manufacturing Indiana (TMMI). This $700 million investment marked a key step in 's strategy to expand its North American production capacity to meet growing demand for larger vehicles in the U.S. market. Groundbreaking occurred in May 1996, initiating construction of the facility on approximately 1,160 acres. The project progressed rapidly, with the plant designed specifically for assembly of full-size pickup trucks and SUVs, incorporating Toyota's principles from the outset. By late 1998, the facility was operational, holding an initial annual production capacity of 150,000 vehicles following an early expansion from 100,000 units. The first rolled off the assembly line in December 1998, with full production ramping up in May 1999 for the 2000 . Sequoia production followed in 2000, targeted for the 2001 , establishing TMMI as a of 's U.S. lineup. These launches represented 's entry into the competitive North American full-size vehicle segment. Early operations faced challenges in scaling production to full capacity and assembling a skilled for the rural location. TMMI began recruiting and training its initial team members in the late , drawing from local communities to build a capable of implementing Toyota's team-based system. The ramp-up process required iterative adjustments to achieve efficient output, with the plant reaching its targeted 150,000-unit capacity by April 1998 in preparation for volume production.

Major Expansions and Milestones

In 2003, Toyota shifted production of the minivan to its Indiana facility, with the first units rolling off the line in for the 2004 model year, marking an early expansion of the plant's capabilities beyond full-size trucks. By July 2008, amid adjustments to North American manufacturing to enhance efficiency, Toyota relocated all pickup production from to its Texas facility, while also scaling back Sequoia SUV output at the Princeton plant due to softening demand for large vehicles. In October 2009, the plant began assembling the Highlander midsize SUV, supported by the addition of the East Plant to increase overall capacity and accommodate the new model line. In 2021, Toyota announced an $803 million investment to prepare the facility for production of two new three-row SUVs, the Grand Highlander and . Production of the Grand Highlander began in August 2023, followed by the in November 2023, marking the first Lexus vehicle assembled at TMMI. On April 25, 2024, announced a $1.4 billion investment in the facility to prepare for production of a new three-row battery electric , with assembly expected to begin in 2026 and the addition of up to 340 jobs. By June 2025, the plant had produced its one-millionth , a 2025 Platinum edition, highlighting its growing focus on electrified models. At that time, cumulative vehicle output since the facility's 1998 opening exceeded 6 million units.

Production

Current Vehicles

Toyota Motor Manufacturing Indiana (TMMI) primarily focuses on producing hybrid SUVs and minivans, with a shift toward hybrid models following expansions in the late . As of 2025, the plant assembles the (gas and hybrid variants), Grand Highlander (gas and hybrid variants), Sienna Hybrid, Highlander Hybrid, and , incorporating advanced hybrid powertrains where applicable and assembly processes tailored to TMMI's facilities. In 2024, TMMI produced a total of 328,136 vehicles, reflecting its role as a major hub for 's North American hybrid output. The and its larger variant, the Grand Highlander, are both s manufactured at TMMI's West and East Plants, serving as the sole global production source outside of . These models feature Toyota's system in hybrid variants, with assembly processes at TMMI optimized for integrating high-voltage batteries and electric motors early in the line to enhance efficiency and . The Highlander's production at TMMI began emphasizing hybrids in recent years, contributing to its popularity in the midsize segment with features like all-wheel drive options and up to 36 mpg combined fuel economy. Similarly, the Grand Highlander, introduced to offer more interior space, shares the same hybrid architecture in electrified versions and is built on the same lines, allowing TMMI to achieve through shared components and flexible manufacturing. In April 2024, Toyota announced a $1.4 billion investment at TMMI to expand capacity for additional hybrid and electrified vehicles. Exclusive to TMMI's East Plant, the Hybrid minivan represents the facility's dedication to family-oriented vehicles with electrified efficiency. Launched in its current hybrid-only form, the Sienna achieves up to 36 combined and includes all-wheel drive availability, with TMMI's assembly incorporating specialized robotic and for its and aerodynamic body. In June 2025, TMMI produced its 1-millionth , a 2025 Platinum, underscoring the model's sustained demand since hybrid production ramped up at the site. This milestone highlights TMMI's expertise in hybrid minivan , where processes like just-in-time battery installation minimize waste and support Toyota's environmental goals. The , a luxury three-row , began production at TMMI's West Plant in November 2023, marking the facility's entry into premium assembly. Built on the same platform as the Grand Highlander but with upscale materials like leather-trimmed interiors and advanced , the TX offers hybrid powertrains delivering 366 horsepower and 34 mpg combined. TMMI's adaptations for the TX include dedicated stations for luxury finishes, ensuring it meets standards while leveraging the plant's hybrid expertise. This model positions TMMI as a key supplier for Lexus's growing lineup in .

Past Vehicles

Toyota Motor Manufacturing Indiana (TMMI) initiated production of the , its first full-size , in December 1998 for the 2000 , marking the plant's debut in assembling vehicles designed for the North American market. This model utilized traditional construction techniques at TMMI, involving separate assembly and body mounting to enhance durability for heavy-duty applications. Production continued until 2008, when consolidated Tundra manufacturing at its facility to streamline operations and reallocate Indiana's capacity toward midsize SUVs. By the end of this period, TMMI had assembled nearly one million Tundras, establishing the plant's expertise in large-truck production. In September 2000, TMMI began producing the , a full-size sharing the Tundra's platform and architecture, which allowed for efficient shared assembly processes focused on robust components. Sequoia output emphasized spacious three-row interiors and towing capabilities, with the plant adapting its lines for -specific welding and techniques unique to this model's larger body. Following the 2008 Tundra relocation and amid slowing sales, Sequoia production at TMMI was reduced, operating below full capacity to accommodate new model introductions, though it continued in lower volumes until a later full cessation in 2022. This shift temporarily impacted plant utilization but enabled diversification into unibody vehicle assembly. The model's production at TMMI highlighted the facility's early heritage.

Plant Layout and Infrastructure

Facility Design and Layout

The Toyota Motor Manufacturing Indiana (TMMI) facility is divided into two primary structures: the West Plant and the East Plant, enabling specialized production flows while sharing certain infrastructure for efficiency. The West Plant primarily focuses on the assembly of the Highlander, Grand Highlander, and vehicles, encompassing dedicated zones for body construction and final integration. In contrast, the East Plant handles production and incorporates additional Highlander assembly lines, which were integrated following a major expansion to enhance overall capacity. In June 2025, TMMI announced an expansion to add Grand Highlander assembly in the East Plant alongside the West Plant to increase production volume, while both plants continue to assemble the , Highlander, and . This division allows for streamlined spatial organization, with each plant occupying distinct sections of the total 4.5 million square feet of manufacturing space. Core production zones within the facility include stamping, where sheet metal is formed into body panels; welding, for joining structural components; painting, applying protective and aesthetic finishes; assembly, where interiors and exteriors are combined; and final inspection areas for quality verification before vehicles exit the line. These zones are arranged in a sequential linear flow to minimize movement and optimize progression from raw materials to completed vehicles, with the stamping and welding sections serving both plants through integrated pathways. The layout supports a logical progression, ensuring that components move efficiently between divisions without unnecessary cross-traffic. Material flow logistics at TMMI emphasize just-in-time delivery, facilitated by the proximity of suppliers located in and around , such as Indiana, which produces seats and door trims nearby to reduce transit times. Internal transport systems, including conveyor lines and dedicated pathways, move parts from receiving docks through the zones to assembly lines, maintaining a continuous and synchronized across the West and East Plants. This arrangement, enhanced by the East Plant expansion in the mid-2010s, supports seamless integration of materials while adapting to varying production demands.

Technological and Sustainability Features

Toyota Motor Manufacturing Indiana (TMMI) integrates elements of Industry 4.0 through advanced systems where employees program robots to perform tasks such as car body panels and painting bumper covers, enhancing precision and flexibility in production. These programmable robots operate in tandem with human workers to increase efficiency while maintaining quality standards. Additionally, TMMI employs harness-like exoskeletons to support workers during elevated tasks, reducing physical strain and promoting safety and productivity. In terms of , TMMI has achieved to status since 2012 by updating programs to capture additional waste streams, resulting in a 19% reduction in waste generation per over that period. The facility's energy-efficient processes have led to a 42% decrease in per since 2012, supported by ISO 14001 environmental management certification maintained since 1999 and recognition for both its East and West plants in 2018. These initiatives align with 's broader goal of carbon neutrality in North American manufacturing operations by 2035, contributing to a 31% reduction in CO2 emissions per at TMMI since 2012. TMMI supports hybrid vehicle assembly for models like the Highlander Hybrid and Hybrid, while preparing for full (BEV) production. In April 2024, Toyota announced a $1.4 billion investment at TMMI, including a dedicated assembly line using lithium-ion batteries supplied from Toyota's facility to support future BEV production. However, assembly of the all-new three-row BEV SUVs was shifted to the plant, with production starting in 2026. This upgrade facilitates zero-emission vehicle manufacturing components, expected to create up to 340 new jobs and advance 's electrification strategy.

Workforce and Community Impact

Employment and Operations

Toyota Motor Manufacturing Indiana (TMMI) employs over 7,650 team members as of 2025, making it a major employer in the Evansville area. The facility operates as a non-union plant, consistent with 's U.S. manufacturing operations, though recent efforts by workers to organize with the have been noted without successful unionization to date. Daily operations involve a variety of shift structures to support continuous production, including standard 8-hour shifts five days a week, 10-hour shifts four days a week, and occasional 12-hour shifts three days a week, with potential or weekend work based on production demands. In April 2024, Toyota announced a $1.4 billion in TMMI to enable assembly of a new three-row (BEV), adding up to 340 high-quality jobs and bringing the plant's total to $8 billion since its establishment. This expansion supports job growth by enhancing production capabilities for electrified , including hybrids and BEVs, while maintaining the plant's focus on efficient . Team members at TMMI engage in operational roles across stamping, body weld, paint, assembly, and final audit processes, contributing to the production of over 328,000 annually. TMMI provides comprehensive training programs to equip employees with essential skills, including certification in the (TPS), which emphasizes principles such as just-in-time production and error prevention to foster continuous improvement. Specialized training covers assembly techniques for hybrid and BEV models, such as the Highlander Hybrid, Sienna Hybrid, and the upcoming BEV SUV, ensuring team members are proficient in handling advanced electrified powertrains and battery integration. Additionally, the plant supports diversity initiatives within operations as part of Toyota Motor North America's broader strategy, which promotes a representing varied backgrounds through recruitment, development, and inclusive practices.

Community Engagement and Contributions

Toyota Motor Manufacturing Indiana (TMMI) has donated over $54 million to local organizations in Gibson County since its groundbreaking in 1996, focusing on initiatives that enhance , health services, and . These contributions include targeted support for educational programs, such as the Toyota Fund dedicated to benefiting K-12 education in the county, and health-related projects like a $1 million lead gift toward the construction of the Toyota Indiana in Princeton, which opened in May 2025 and provides community wellness facilities. Additionally, TMMI's extends to economic development efforts, including multimillion-dollar investments through the state's READI initiative to fund and community facilities that bolster local growth. TMMI fosters employee volunteerism as a core component of its community outreach, with nearly 1,000 team members participating in company-led initiatives in 2024, collectively contributing over 10,000 hours of service. A prominent example is the long-standing partnership with of Evansville, spanning nearly 30 years, where employees volunteer to construct affordable homes; in 2025, this collaboration advanced with the opening of a new indoor volunteer center designed using principles from the (TPS). The TPS-inspired approach incorporates standardized work processes, part staging, and a for panelized construction, reducing build times by two days per home and enabling year-round production to increase annual home output by five units, thereby amplifying the program's impact on housing accessibility in the region. Beyond direct philanthropy, TMMI generates significant economic ripple effects in Gibson County through its operations and expansions, supporting approximately 80 suppliers statewide that create additional jobs and stimulate local supply chains. Plant expansions, backed by an $8 billion total investment, have spurred infrastructure enhancements, including for community projects like the and developments that improve regional accessibility and economic vitality. This outward impact complements TMMI's workforce of over 7,600 employees, enabling robust participation in these community efforts.

References

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