A deadly explosion at a key supplier’s factory in Japan has triggered a growing production halt for Toyota, affecting the manufacturing of some of its most popular models, including the RAV4 and Harrier crossovers. The disruption — which stems from a March 6 blast at Chuo Spring Co.’s facility in Toyota City — has now cascaded across multiple Toyota-affiliated plants, prompting concerns over potential impacts on global vehicle shipments.
Production Halts Spread Beyond Initial Sites
What began as a localized shutdown for safety checks has evolved into a wider disruption, affecting assembly lines operated by both Toyota and its affiliated companies. Initially, Toyota paused operations on the morning of March 10 at two domestic factories. The company has since extended that suspension into the afternoon and halted the March 11 morning shift as well.
Models and Plants Affected
The following production lines have been impacted by the fallout:
- One of two lines at Toyota’s Takaoka plant, which builds the RAV4 and Harrier crossovers
- Two lines at Toyota Industries Corp.’s Nagakusa factory, which also produces the RAV4
- One line at Daihatsu’s Kyoto plant, responsible for manufacturing the Toyota Probox
- Daihatsu’s Shiga factory, where models like the Tanto minicar are produced, has also been shut down, according to local reports
Toyota spokesman Jean-Yves Jault emphasized that “safety is Toyota’s top priority” and confirmed that investigations are underway at the Chuo Spring facility to determine the cause of the accident.
U.S. Shipments of RAV4 Could Be Affected
Though Toyota has not confirmed the precise impact on its export schedules, the temporary loss of production capacity could ripple into international markets — especially the United States. In 2023, Toyota sold more than 475,000 RAV4 units in the U.S., with roughly 21 percent of those — over 100,000 vehicles — imported from overseas. The company said it will reassess operations on March 11 but has yet to disclose how the disruption may affect overall production output or export volumes.
Explosion Raises Safety Concerns at Chuo Spring
The explosion at Chuo Spring’s Fujioka facility killed one worker and injured two others. The incident reportedly involved a dust collector, though the exact cause remains under investigation. This marks the second major explosion at the same plant in less than two years — the previous incident in October 2023 had already raised alarms about safety practices.
A Troubled History
The earlier explosion was attributed to a clogged air duct on the painting line’s drying furnace, which led to a dangerous gas buildup and subsequent ignition. That event injured two workers and took Toyota 10 days to recover from in terms of production. Following the incident, Chuo Spring implemented new safety protocols, including enhanced filter inspections, emergency shutdown procedures, and additional staff training.
Despite those efforts, the recurrence of such a serious accident has sparked renewed scrutiny. In its latest statement, Chuo Spring offered condolences to the family of the deceased and pledged to overhaul safety practices before resuming operations. “We will first ensure our employees can work with peace of mind before proceeding with any production restarts,” the company said.
Strategic Importance of Chuo Spring
Founded in 1988, the Fujioka plant produces critical automotive components including chassis springs, controller cables, and precision parts. Toyota holds a roughly 24 percent stake in Chuo Spring, making the supplier a vital cog in the automaker’s domestic production network.
What Comes Next?
As Toyota continues to assess the fallout, the company is looking into options for recovering lost output. However, with multiple facilities offline and a crucial supplier incapacitated, the path to full recovery may not be swift. For now, uncertainty lingers — not only for Toyota’s Japanese operations but potentially for overseas markets relying on vehicle imports.
With safety reviews ongoing and production lines at a standstill, the incident underscores the vulnerability of even the most efficient supply chains when a single point of failure — particularly one involving human tragedy — brings everything to a halt.
