How much work previously done with physical models is now virtual?
About 80%. It used to be that only the most skilled technicians could evaluate new models, determining where it might be hard to insert a hand or a tool on the production line and other things like that. But rather than rely solely on veteran workers, it’s now done with computers. Instead of bringing in hired guns, we retrain our staff to use the new technology. Computer experts, almost by definition, don’t know a lick about cars. Q: How much does computer technology help cut costs? A: By a vast amount, mostly by reducing the need for prototypes. Consider that Toyota’s entire product line has grown by roughly 50% in just 10 years. For example, the Vitz subcompact model has four derivative cars [sharing the same platform and engine] such as the FunCargo wagon, a small sedan version [sold in the U.S. as the Echo] and the bB hatchback. So the number of models is up dramatically. We’ve gone from about 40 models to more than 60. And that’s all basically without having increased the number o
