Training the Young: Impering Knowledge and Abilities from Elders in the Seventh Installment
Toyota Revives First-Generation Crown with Sustainable Materials and Master Craftsmanship
Toyota's Raw Material Development Division has played a pivotal role in the restoration of the iconic first-generation Crown, blending innovative recycling technology with traditional master craftsmanship to create a more sustainable and faithful replica.
The Division's contribution is evident in the use of advanced recycled materials and technologies in parts manufacturing. For instance, high-quality recycled plastics derived from Automotive Shredder Residue (ASR) have been adopted for the Crown's front fender seal, thanks to the Division's expertise in advanced gravity separation technology. This pioneering approach to Car to Car recycling is championed by Toyota Tsusho Group companies involved in automotive recycling.
In terms of technologies used in the restoration process, Toyota leveraged cutting-edge fabrication methods alongside exquisite craftsmanship. The engine was meticulously dismantled and rebuilt using precise restoration techniques that preserved original details while enhancing performance. Furthermore, paintless technology applied to car bumpers, where materials are colored intrinsically and repaired by skilled polishing, has been employed. This technique, requiring mastery in mold polishing and craftsmanship, remains critical despite advances in automation.
The project, which started at the Motomachi Plant in the spring of 2022, involves a diverse group of skilled members, including veterans and junior staff. Shuji Shudo, materials team leader, oversees the production of interior and exterior parts. Shinji Tanaka works on restoring and fabricating the car's tail lamps and other lights, with assistance from the Raw Material Development Division.
Zinc alloy casting is a challenge for the team due to its low melting point and the fact that it's a vanishing technique within Toyota. Nagato and her peers refined the plan for how metal is poured into the sand mold and the cooling method to overcome issues with zinc alloys. Shudo and the Raw Material Development Division staff used welding rods made from antimony to fill in and level surface pores on zinc alloy parts. The Division also has the technology and expertise for eliminating air bubbles in the form of degassing equipment.
The team aims for a "better-than-new" quality for the restored Crown. Restoration of the badly rusted body requires the mastery of highly skilled craftspeople and a new metalworking technique called incremental forming. Naomichi Terada, a die casting expert, was consulted to make the intake manifold and related key engine parts.
The project also serves as an opportunity to transfer skills from veterans to younger generations. Nagato learned a lot from working with Motoki and other casting experts that she didn't know before and wants to share what she has gained with those who come after her. Tanaka tested various types of acrylics to find the right one for the tail lamp parts, eventually working with a younger staff member, Ats, to arrive at a suitable acrylic material.
This ambitious restoration project reflects Toyota's commitment to preserving its heritage while pushing the boundaries of sustainability and craftsmanship. The first-generation Crown, restored with a blend of innovative technology and traditional master craftsmanship, is set to make a comeback, embodying Toyota's dedication to monozukuri—the art of manufacturing.
The Raw Material Development Division's expertise in advanced technology has been instrumental in manufacturing parts for the restored first-generation Crown, with the use of recycled plastics from automotive shredder residue being one example. Toyota's commitment to sustainability extends to the financing sector, as Toyota Tsusho Group companies involved in automotive recycling champion a pioneering approach to car-to-car recycling.
Moreover, the restoration process for the iconic car integrates cutting-edge fabrication methods, such as paintless technology on car bumpers, with intricate craftsmanship, demonstrating Toyota's dedication to the art of manufacturing, or monozukuri.
The finance industry is also involved in promoting this project, as the revived first-generation Crown serves as an opportunity for skill transfer from veterans to younger generations, fostering continued growth and innovation in the manufacturing and automotive industries, supported by financial backing.
