Suganuma has racked up more than two decades in body manufacturing in Japan and overseas. His mission, he says, is to train every Lexus worker in his division to develop the same instinctive feel for the job. It's not just about teaching new skills. It's about transferring a care and knowledge passed on through generations. "We're training them to have pride in the quality of their own work," says Suganuma.
Much of the early-stage body welding is done by robots but the robots are programmed, or "taught", by the takumi. But when it comes to carefully adjusting and bolting on parts, workers do almost everything by hand. The process of fitting the parts together precisely is where you need highly developed skills. When guiding his team, he urges them to go beyond what the original designs call for. "It wouldn't be Lexus craftsmanship if we didn't strive to go beyond what's asked of us," says Suganuma. "It's a very strong part of our identity to always go a step further."
In the final zone before it is sent for painting, takumi are busy at work on the body. They have just a couple of minutes to make fine adjustments to the parts such as the bonnet, doors and trunk and to check the body has been securely welded together. While each body is different, in the same way that each person's face is different, the takumi can tell right a way if a part's alignment is off by a millimetre. To keep them on their toes, Suganama sneaks a body that is below standard onto the production line every day. Not one has ever slipped past his team. "We mass produce cars. But if you put yourself in the customer's shoes, there's only one car that matters: the one they own."
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