The construction schedule
Toyota takes two to four years from groundbreaking to first vehicle, phases never skipped. Compressed here to quarters, with hard exit gates — no calendar dates, because dated plans rot and gated plans don’t:- Phase 0 — Stop the line. Known red andons outrank all new work: stale credentials retired, the export pipeline fenced until it carries real context. Exit gate: no known red andon.
- Phase 1 — Build the organization. The first compiled gates land — work-order schema, skill-gate enforcement, germline protection, handoff validation. Exit gate: a nonconforming work order physically cannot enter the queue; a germline file physically cannot change without review and changelog.
- Phase 2 — Trial production. Five pilot units, hand-built through all seven stations — cardboard engineering with real cardboard — the standard work revised after each. Exit gate: one unit of each family holds a valid certificate; the standard work’s changelog has five or more entries; first-pass yield is measured, whatever it is.
- Phase 3 — Run at rate. Sustained takt — 3 to 5 certified units a week — with WIP limits enforced and the silence andon live. Exit gate: one full cycle at takt with zero silent stalls — every gap in flow produced an alarm, and every alarm produced a response.
- SOP — Start of production. The line runs; kaizen begins metering its 10% budget; the pilot team hands daily quality to the workers it built; the operator’s attention retreats to the two takt-bound touches plus the obeya.