Most everywhere in the world except the US, the Toyota Hilux is prized as a tough, versatile, and reliable four-wheel drive midsize pickup truck. The Hilux is a practical choice for both commercial and personal use, from construction sites in bustling cities to unpaved roads in rural landscapes. Confident off-road as well as on city streets, this popular work truck is found in a myriad of environments for which it was never intended.
“Hilux” is a portmanteau of “high” and “luxury,” but there’s nothing luxurious about the Hilux. Reviewers often note its utilitarian, spartan interior and stiff handling. It’s not a smooth or quiet ride over paved roads. Nevertheless, the Toyota Hilux is dependable, tough, and has the horsepower and torque to haul a substantial load (in the US, one can argue that the Ford F-150 best serves this role). The Hilux is available from Toyota dealerships in Europe, the UK, Australia, New Zealand, the Middle East, Africa, South America, and Central America in single cab, extra cab, and double cab body styles with four trim levels.
The Toyota Hilux was introduced in Japan in 1968 and entered the US market in 1972. In 1976, Toyota Motor North America, Inc. rebranded the Hilux as the “Toyota Truck” or “Toyota Pickup,” the name “Hilux” being too enigmatic for North American markets. It was sold in the US until 1995, when it was succeeded by the Tacoma pickup truck. The Toyota Hilux is one of the most popular light commercial vehicles in the world, but high tariffs and safety & emission regulations dissuade most North Americans from importing one of their own.
Today, the Hilux and Tacoma are separate vehicles for different markets. The Tacoma is designed for American tastes, with beefier bodywork and more “attitude,” along with luxury options that are unique to the model. The Tacoma, while larger than the Hilux, is optimized to be a daily driver. The utilitarian Hilux, by contrast, is smaller and lighter than popular pickups in the US. The style is spartan, with a no-frills exterior and durable plastic interior. The Toyota Hilux range is mostly diesel, uncommon in the US outside of commercial vehicles. While upfront costs are higher, diesels generally have a longer lifespan and better fuel economy than gasoline equivalents. Diesels also provide higher torque at lower RPMs than gasoline engines, providing more pulling power. The Toyota Hilux thrives on work sites.
The Toyota Hilux is now associated with roles for which it was never intended, and which Toyota could not have anticipated. It’s tough enough to customize without overstressing the machine. Modifications expand the capabilities of the Hilux, but Toyota’s proven engine, drivetrain, transmission, and electronics are usually kept stock. For extreme customizations, suspensions, wheels, and even the frame may be replaced.
The Hilux can be found performing a multitude of unintended roles. The Red Cross, United Nations, WHO, and UNICEF use Hilux pickups in the field, as do militant insurgents and drug runners. Plentiful aftermarket accessories extend where the Hilux can travel: Enhanced suspensions, reinforced chassis, all-weather alternators, satellite and radio antennae, winches, roof racks, hi-beam lights, snorkels, row bars, and more. Truly inventive modders can convert a stock Hilux to serve most any role.
The Toyota Hilux is a remarkably reliable and versatile vehicle. The following accounts demonstrate how the Hilux earned its reputation as a tough-as-nails workhorse.
How it’s Made: Toyota’s Incomparable Manufacturing
Today, the Toyota Hilux is in its eighth generation. The Hilux’s enduring popularity is a testament to Toyota’s commitment to quality.
In 1926 Sakichi Toyoda (1867-1930) founded his company, the Toyoda Automatic Loom Works Ltd., a machine manufacturer. Sakichi Toyoda was a savvy businessman who recognized the importance of long-term planning, and also a philosopher who realized the worth of the individual’s contribution to a company’s prosperity. His core principles – success through self-improvement and respect for the individual – guide Toyota today.
In 1933, Toyoda, recognizing a need for a domestic Japanese auto industry, established a nascent automotive department. Toyota Motor Co., Ltd. (the name change to “Toyota” was adopted for good luck) was founded in 1937 under the direction of the founder’s son, Kiichiro Toyoda (1894-1952). Toyota Motor Co., Ltd. established its first US showroom in 1957.
Today, although it’s an international conglomerate, Toyota is still run as a family company (even though the Toyoda family does not control the company stock). Toyota’s goal is to be the best, if not the biggest, through continual improvement, efficient manufacturing, and steady growth. Toyota manufactures its vehicles worldwide, adapting its management system for rapport with local customs and expectations. Models are adapted for regional laws and regulations, and also for consumer tastes (hence the lack of availability of the Hilux in the US).
How does Toyota mass-produce a vehicle as solid as the Hilux? The patented Toyota Production System (TPS) is a globally recognized management system that’s revered for its profitability. TPS ensures high quality, low cost, and fast development turnaround. Thirteen “pillars” define TPS, all aiming to ensure quality, efficiency, and the elimination of waste. TPS has enabled Toyota to constantly improve the Hilux and other models, making it the exceptionally capable vehicle that it is today.
The Thirteen Pillars of the Toyota Production System (TPS)
TPS ensures quality, efficiency, and the elimination of waste in manufacturing. It’s a patented management system that is continually refined by Toyota Motor Co., Inc.
- Andon, highlighting a problem, a term derived from the flashing lights of a stopped assembly line.
- Jidoka, “automation with a human touch” or, as Toyota defines it, “autonomation,” empowers all employees. Any employee on the line can halt production if a defect is spotted before the problem continues downstream and causes other problems.
- Gemba, “workplace” or “where the work gets done,” specifically the factory floor, emphasizing open floor plans and cross-communication. Walking the floor is expected of Toyota managers and executives.
- Genchi Genbutsu, “go and see for yourself,” fosters a personal understanding of a problem.
- Hansei, “self-reflection,” or humbleness in identifying failures and ways to improve.
- Heijunka, “production smoothing,” to guide Toyota’s strategic inventory control.
- Kaizen, “continual improvement,” a key philosophy of the Toyota Production System. Toyota employees are expected to identify and share any ideas for improving standardized procedures.
- Kanban, “signboard,” for communication between processes, ensures that defects aren’t passed down the assembly line, that inventory is adequately supplied without waste, and that production fluctuations are reduced or eliminated.
- Muda, “waste,” not just the consumption of resources but also inefficient procedures and even blame. Toyota identifies muda in shipping and transportation, overstocked inventory, wear & tear, waiting, overly complex tools or workflows, overproduction, and defects.
- Mura, “unevenness,” this just-in-time (JIT) principle is the elimination of irregularities in production.
- Muri, “overburden,” a second JIT principle, allowing sufficient time to complete a task correctly.
- Nemawashi, “going around the roots” or “laying the foundation,” seeks opinions from all employees before making a decision.13. Poka-Yoke, “mistake-proofing,” are failsafes that stop the production line when a mistake happens.