At the 29th Annual Applied Ergonomics Conference, MTM once again brought forward a practical, people-focused solution to the Ergo Cup® Competition: the LLC Cap Remover. The Ergo Cup® is a conference where companies come together to present innovative solutions that address ergonomic challenges in the workplace and improve processes and systems.

On the Discovery Line, team members in Assembly-specifically in the final liquid fill area-were required to repeatedly grip and remove an LLC cap, resulting in upper-extremity strain over time. The opportunity to improve the removal process became clear, allowing team members to perform the task more safely and efficiently.

The project also reflects how creativity and technology are changing the way workplace challenges are solved. With the accessibility of tools like 3D printing, teams can now rapidly create custom solutions that would have been significantly more difficult, costly, and time-consuming to develop just a few years ago.

Removing LLC caps required repeated manual effort throughout the shift, often involving awkward wrist positioning, grip force, and repetitive upper-body motion. Team members described strain not only in the hands and wrists but also in the shoulders and upper arms due to the force and repetition required to consistently complete the task throughout production. Although the task itself may have appeared small, the frequency of the motion made it a meaningful ergonomic concern. Over time, the repetitive strain caused discomfort and increased the risk of injury for team members who performed the process daily.

Beyond the physical strain on team members, repetitive ergonomic issues can also have a significant operational impact. When injuries occur, costs extend far beyond immediate medical treatment and can include administrative expenses, incident investigations, recovery time, time away from the line, retraining, and coverage for affected team member roles. Using estimated injury-related costs of $25,000 per incident, even a small number of ergonomic injuries can have a substantial long-term impact on both team members and operations.

Recognizing both the immediate and long-term risks, the team knew a better solution was needed, one that would not only improve the process but also better support the people performing the work every day.

Rather than settling for a temporary fix, the team leaned into Kaizen, continuously refining their approach until they found a solution that not only worked but also truly supported team members.

Using 3D printing, they were able to quickly prototype and adjust designs, creating a tool tailored specifically to the task. Each iteration brought improvements, guided by real-world use and team feedback.

At MTM, innovation drives everything we do. By collaborating across departments and embracing continuous improvement, we enhance safety, quality, and efficiency throughout our operations.

“I had so much pride in seeing our team present the project and recognize the value in the small but significant change that they were a part of,” shared Ashley, an MTM team member involved in the project. “It was inspiring and reassuring to see other companies that also value engagement, ergonomic improvement, and the many benefits that come with those.”

The project reflects MTM’s continued commitment to teamwork, innovation, and continuous improvement. By staying focused on supporting team members and embracing creative problem-solving, even small changes can create a lasting impact.

Last November, members of the Mazda Toyota Manufacturing (MTM) leadership team traveled from Huntsville, Alabama to Toyota Battery Manufacturing North Carolina (TBMNC) to celebrate an exciting milestone: the plant’s Start of Production. TBMNC produces the batteries that power the Corolla Cross Hybrid Electric Vehicle (HEV), an important component that supports hybrid vehicle production connected to MTM.

The trip itself highlighted the technology behind the collaboration, with the team making the drive to North Carolina in a Corolla Cross Hybrid

TBMNC plays a critical role in the hybrid production process. The batteries produced at TBMNC support the Corolla Cross HEV, demonstrating how multiple Toyota facilities work together to bring advanced vehicles to life.

This collaboration shows how innovation moves across facilities, from battery production in North Carolina to vehicle assembly connected to MTM, helping deliver high-quality hybrid vehicles to customers.

During the visit, MTM leaders connected with TBMNC team members to recognize their dedication and hard work leading up to the start of production. To celebrate the milestone and appreciation, the team shared MTM swag with TBMNC employees as a small token of thanks.

The visit reinforced the strong collaboration between TBMNC and MTM and the important role each facility plays in supporting hybrid vehicle production.

The event, themed “STEM Isn’t Spooky,” was part of the All Girls Auto Know® program and was hosted in partnership with the Southern Automotive Women’s Forum (SAWF) and Madison City Schools. A group of 54 students stepped inside a real manufacturing environment to learn how science, technology, engineering, and math power the automotive industry.

Throughout the day, students rotated through three themed activities designed to bring STEM concepts to life while highlighting how they are applied in manufacturing.

All Girls Auto Know® is SAWF’s middle school outreach program designed to introduce young women to career opportunities in automotive and STEM fields. Each one-day event can host up to 300 middle school students, providing hands-on activities that showcase the wide range of careers available in the industry. For many students, the event offered their first look at how STEM concepts are applied in a real-world manufacturing setting. From chemistry and engineering to teamwork and problem-solving, the day showed that innovation can be both exciting and accessible.

Events like All Girls Auto Know® are made possible through strong partnerships. MTM is proud to collaborate with Southern Automotive Women’s Forum and Madison City Schools to create opportunities that inspire curiosity and expand students’ understanding of STEM careers.

This fall, Mazda Toyota Manufacturing was honored with the 2025 Community Philanthropy Award at the 16th annual Summit on Philanthropy, hosted by the Community Foundation of Greater Huntsville. This recognition reflects MTM’s deep commitment to community investment and the positive impact our team has delivered across North Alabama.

The Summit on Philanthropy honors individuals and organizations whose generosity nurtures long-lasting change in our region. MTM was selected as this year’s recipient for its thoughtful, sustained support of nonprofit partners and initiatives that strengthen education, economic development, and quality of life throughout Madison, Limestone, and Morgan counties.

Since its founding in 2018, MTM has invested more than $2.5 million in North Alabama through corporate giving and the MTM Grant Fund, which is hosted and administered in partnership with the Community Foundation of Greater Huntsville. In 2025 alone, the grant fund exceeded $1 million in awards to nonprofit organizations and community programs, driving measurable impact in our region.

“Many people don’t realize that there is only one Mazda Toyota Manufacturing in the world, and it exists right here in Huntsville, Alabama,” said Rhonda Gilyard, MTM’s Vice President of Administration. “That is why it is so important to us to invest in this community: to invest in the people who live here, and not just the ones who work for us.”

The MTM Grant Fund was created to engage local nonprofits in a collaborative effort to support meaningful programming in three core areas:

• Education
• Economic impact
• Quality of life

These priorities reflect our philosophy of Mendomi: caring for one another like family and investing where we live and work.

At the Summit on Philanthropy event, community leaders and partner organizations shared heartfelt testimonials about the impact of MTM’s work. Our partners, including educators, nonprofit leaders, and civic stakeholders, spoke to the real-world difference that sustained local investment makes in people’s lives.

We were especially humbled by Governor Kay Ivey’s touching message, which highlighted MTM’s growing legacy as not just a major employer in the region, but also a community partner committed to strengthening North Alabama beyond the factory gates.

MTM’s philanthropy extends beyond financial grants. Our team members actively engage with the community through volunteer efforts, school support initiatives, and year-round giving programs. From backpack drives to trail clean-ups to community celebrations, MTM’s commitment is people-first and purpose-driven.

This award recognizes the relationships we’ve built, the organizations we’ve supported, and the neighbors whose lives are touched by collaborative investment.

As we reflect on this honor, we are reminded that MTM’s success is intertwined with the strength of the community around us. Every partner, nonprofit, educator, and community leader who shares this vision has played a role in shaping a more vibrant North Alabama. We are grateful for the opportunity to give back, to learn from others, and to continue investing in this region.

This August, MTM announced a partnership with Morgan County Schools Technology Park and Huntsville City Schools Center for Technology to launch the LIGHT Program: Leading Industry Growth by Helping Teachers.

At its core, the program is about connection: coupling classrooms with real-world industry expertise and connecting students with the skills and confidence they’ll need for future careers.

Through LIGHT, MTM will provide an instructor’s aide who brings hands-on industry knowledge directly into classrooms. Starting in August 2025, MTM Group Leader, Courtney Franklin, will serve in this role, rotating between the two school districts to support teachers and inspire students with her technical expertise.

The program will initially launch at Brewer High School and the MCS Technology Park in Morgan County, as well as the brand-new Center for Technology in Huntsville City Schools.

This isn’t MTM’s first step into education. Since breaking ground in 2018, Mazda and Toyota have contributed over $750,000 toward STEM education and workforce development in North Alabama. In 2022, MTM also began its Grant Fund, which has since distributed nearly $1 million to support school districts, STEM initiatives, and workforce programming.

Franklin will support Huntsville City and Morgan County schools for up to three school years, with the opportunity to rotate into other districts as the program expands. MTM hopes this model will not only grow across North Alabama but also inspire other industry partners to join in.

“Ultimately, we’d love to see this kind of collaborative program benefitting even more students and building stronger pipelines to industry,” Fernandes concluded.

That’s why we’ve developed a comprehensive education outreach program designed to spark curiosity and highlight career pathways in manufacturing.

“It’s a holistic approach,” offered Rylee A., Education and Community Partnerships Specialist.

MTM’s hands-on approach to student engagement starts as early as elementary school, where we support STEM education through fun, hands-on learning. For example, MTM recently supported Horizon Elementary School’s STEM class, as students were tasked with creating an attachment for their robot vehicle to protect a fragile “passenger”—an egg. Activities like this allow students to connect classroom learning with real-world problem-solving.

As students grow, so do the opportunities to connect with our team. MTM regularly:

One of our most impactful initiatives is our Annual High School Senior Day of Work. This is an opportunity for graduating seniors to participate in the application process for a production team member position. As a one-day field trip, students work in the vehicle cabs, take an online test, complete job-placement optimization, and participate in an interview. Those who pass are able to walk across the stage at graduation with a contingent job offer in hand.

Our commitment to engagement doesn’t stop once a student graduates from high school. MTM continues its education partnerships at the post-secondary and collegiate levels. MTM partners with local community colleges, such as Calhoun, Drake State, and Wallace State, through the FAME apprenticeship program, which blends classroom instruction with paid, hands-on work experience.

MTM also has a college internship program, in partnership with the Alabama Productivity Center, for juniors and seniors pursuing degree programs such as engineering, business, supply chain & logistics, human resources, and related fields. This is an opportunity for students to gain exposure to the dynamic work environment and support a process improvement through a tangible project.

MTM prides itself on its commitment to students and building a workforce pipeline. Since 2023, we have reached nearly 25,000 students through our education outreach efforts.

Email our Education & Community Partnerships Specialist at engagements@mazdatoyota.com.

At this year’s 28th Annual Applied Ergonomics Conference, MTM once again showcased its culture of innovation and collaboration by entering the Ergo Cup® Competition. Representing the Tool & Die Maintenance team from our Stamping Shop, our project highlighted a homegrown ergonomic solution: The Side Pin Extractor.

The Ergo Cup® Competition recognizes creative solutions that address workplace ergonomic challenges. Projects are judged on innovation, employee involvement, ergonomic risk reduction, and business impact, and our Side Pin Extractor delivered on all fronts.

Before our kaizen, removing stuck pins from stamping dies was a physically demanding and inefficient process. Team members used a slide hammer that required high force and awkward posture, often for extended periods. Some extractions took up to 7–8 hours per pin, increasing the risk of injury and production downtime. The constant need to rebuild slide hammer thread adapters only added to the inefficiency.

Without any prompting from management, team members in Tool & Die identified the hazard and took initiative. Using scrap materials, they designed and fabricated a new Side Pin Extractor that threads into the pin and uses a simple hex nut to apply pulling force. The device can also integrate with a portable hydraulic jack, already in use in the shop, for added efficiency.

Through three major design kaizens—each informed by feedback from team members across shifts—the tool evolved to its current state. The final version is not only effective and safe but also easy to store on preventative maintenance carts, saving additional walk time.

The results speak for themselves:

We’re proud of the Tool & Die team’s commitment to safety and continuous improvement. Special thanks to Jacob P., John K., Tony M., Craig G., Garrett C., Jason D., Ken B., and Daniel B., as well as every Tool & Die team member who contributed to the design iterations.

At MTM, even our smallest teams drive significant change. The Side Pin Extractor is more than just a tool—it’s a testament to the power of collaboration and the ingenuity of our people.

At this year’s Applied Ergonomics Conference, MTM proudly submitted a second entry to the Ergo Cup® Competition—this time from our Discovery Logistics team. The project, known as the Tote Slide, showcases the power of collaboration and rapid innovation in eliminating a persistent ergonomic burden in one of our highest-risk areas.

The Ergo Cup® Competition celebrates practical, impactful solutions to workplace ergonomic challenges. Projects are evaluated based on innovation, employee involvement, risk reduction, and business impact, and this one delivered results that checked every box.

Before the kaizen, team members in Logistics were manually lifting wire harness totes into the heater barn—a tight, repetitive task that placed significant strain on the body. It was one of the top injury-risk processes in the Internal Logistics Shop due to awkward lifting and constrained movement.

Working side-by-side with team members, the internal Kaizen team developed a simple but highly effective solution in just four days. The Tote Slide allows tugger operators to pull directly up to the delivery point and slide totes into place, eliminating the need for lifting.

The tool was designed and fabricated in-house, undergoing multiple iterations based on feedback from team members. Kaizen team members even performed the job themselves to understand the pain points and ensure the solution directly addressed them.

Not only did the Tote Slide dramatically improve safety, but it also has strong potential for scalability. The same concept could be applied to other tugger delivery processes involving flow racks or similar equipment across the facility.

This project reflected MTM’s commitment to cross-functional teamwork and continuous improvement. Key contributors included Joel D., Will R., Josh Y., Shayna L., Dave W., and Kaleigh F., with the support of the entire Discovery Logistics team.

Their passion and creativity exemplify what MTM stands for—empowering team members to solve real problems, reduce risk, and build a safer, more innovative workplace for all.

At MTM, Earth Month is an opportunity to inspire change, both within our organization and in our communities. What we look forward to most during this time is the ability to raise environmental awareness among our team members. It’s a chance to reflect on the impact of our everyday processes and explore ways to improve MTM’s environmental performance. But beyond the workplace, it’s also a time to encourage personal sustainability efforts that extend into our North Alabama communities.

One of the most meaningful aspects of Earth Month at MTM is our collaboration with local community partners. We proudly welcome organizations onsite to share their missions, highlight the essential work they do, and educate our team members on how they can get involved. 

Cross Check is an activity where two team members, who run the same process from each shift, come together to discuss their difficulties and figure out ways to improve their process. But in MTM’s Assembly shop, Cross Check is so much more.

MTM’s Manufacturing Excellence Department (MED) had a goal to create a Cross Check program that was not a “copy and paste” of another NAMC program but instead designed to serve MTM’s unique needs best. Our Senior Vice President David Fernandes challenged the team to launch Cross Check in Assembly by September 2024. As someone who thrives on challenges, I accepted.

We benchmarked strategies with other facilities that have well-established Cross Check activities and brought those learnings back to MTM.

The most important goals to achieve with our Assembly Cross Check program was to address team members’ happiness and understanding of their role within MTM. To accomplish this, we focus on teaching standardized work and how each team member’s job affects the team. We want them to feel empowered to use their voice to create better processes for everyone.

Group Leader Melissa Kirkpatrick is leading the Cross Check team with great energy, a deep understanding of Assembly Production, and the ability to motivate those going through Cross Check. Melissa added that Mendomi-touch (treating each other like family) by developing Cross Check t-shirts and certificates for completion of the program for our team members.

Collaboration plays a major role in the success of Assembly Cross Check. Melissa and I worked together and utilized the 4 Es: Educate, Engage, Empower, and Encourage.

Starting with Educate, we take two weeks to educate team members on all aspects of the plant. We achieve this through tours of other shops and on-the-floor training, such as reviewing FMDS boards.

This leads into Engage, ensuring we educate our team in engaging and fun ways. We play games that reinforce learning and understanding the importance of building a foundation, as well as embodying MTM’s Core Values: Motivate, Appreciate, Relate, Collaborate, and Innovate, both in and outside the workplace.