Toyota SA is back on track after devastating floods
Remember the floods that devastated the KZN South Coast a few months ago? It was truly horrific to see the destruction caused however, we are South Africans, we are resilient. One of the worst hit areas was the Durban South Coastline and in particular the Toyota South Africa Motors Prospecton Plant. The plant was hard hit by raging water, mud and debris. The damage was so severe that officials had to shut the plant down. Was this the end for TSAM?
We recently joined them at the official reopening of the manufacturing fatality which was an incredible occasion considering the amount of damage done to the plant. Experts expected the plant to be down for at least 12 months but due to a collective local and global effort, Toyota started manufacturing after just 3 months.
Now, all lines are up and running and one of South Africa’s biggest auto manufacturers can once again continue adding to the local economy. TSAM was enjoying a healthy market share of 30% – on average – before its production plant in Durban was submerged in water. The automotive giant's market share took a dive, shrinking to 17%, 18,1% and 16,3% in the months of May, June and July – respectively. Despite this, Toyota held on to its number-one position in sales.
TSAM’s Prospecton Plant produces Corolla Cross and Quest as well as segment leaders Hilux, Hiace Ses’fikile and Fortuner – while also assembling a variety of Hino commercial vehicles. The Corolla Quest production line has been activated at the time of writing this article. While production might not be at 100% capacity, the plant is quickly moving towards that.
While the organisation had genuine concerns about witnessing the trail of destruction at the plant, its first priority was the safety and welfare of its employees, contractors as well as their families. This was followed by support to dealers, suppliers, affected communities, and then the recovery of plant operations.
The process towards the plant’s full recovery has been long, with pre-floods level forecasted to be achieved in December. Prior to the floods, operations at the Prospecton Plant were halted due to COVID-19 induced lockdowns in 2020 as well as the civil unrest that brought most businesses to their knees in 2021.
It also became clear that while there were more than 4 000 vehicles damaged on site during the floods, the costliest damage was to the plant infrastructure itself – including robots and other machines. These needed replacement and where that wasn't possible, many had to be cleaned. It was a task that saw employees from various departments climb in to assist.
Much of the factory floor was covered by a metre of muddy water, so mud had to be removed by hand as much as possible. In fact, as Kirby referenced one of his colleagues: “There was not a single square metre of the entire 87 hectares facility that was not affected. In fact, it would be easier to just build a new plant.”
Yet with hard work and dedication the plant has recovered, Japan gave unwavering support, UK and other markets have dispatched parts and Toyota even assisted its suppliers in the area to get back to operational capacity. It was a team effort and one which reaffirms the brands commitment to SA despite the camalites we face.
Also worth a look: the Toyota Everest and the Toyota Corolla Cross: Still King of the Crossover Castle?.
FAQ
Q: Which Toyota models are manufactured at the Prospecton Plant?
The Prospecton Plant produces the Corolla Cross and Quest, as well as segment leaders like the Hilux, Hiace Ses'fikile and Fortuner, plus they assemble various Hino commercial vehicles there too.
Q: How long was Toyota's Prospecton Plant closed after the KZN floods?
The plant was shut down for just 3 months after the devastating floods, which was impressive considering experts expected it to be down for at least 12 months.
Q: What happened to Toyota's market share during the plant closure?
Toyota's market share dropped from a healthy 30% average to 17% in May, 18.1% in June, and 16.3% in July, but they still managed to hold onto their number one position in sales.
Q: Is Toyota SA's Prospecton Plant back to full production capacity?
The plant is operational with all lines running, but it's not quite at 100% capacity yet, though they're quickly moving towards full production levels.
Q: What was Toyota's priority during the flood recovery?
Toyota's first priority was the safety and welfare of their employees, contractors and their families, followed by supporting dealers, suppliers, affected communities, and then recovering the plant operations.
Should You Buy It?
While this article focuses on Toyota's manufacturing recovery rather than specific vehicle recommendations, the fact that Toyota SA bounced back so quickly after devastating floods shows their commitment to the local market. If you're considering a Toyota, the Hilux remains the best bakkie under R600,000 in SA, starting from around R489,900 for the 2.0 VVTi single cab. The Corolla Cross, now back in production at Prospecton, offers excellent value as the best compact SUV under R450,000, with pricing from R389,900. Toyota's proven reliability, strong dealer network, and the fact they're manufacturing locally again makes any of their vehicles a solid buy right now. Just remember, with production ramping up after the floods, delivery times might still be longer than usual, so get your order in early if you want one of these popular models.
