Having workers pass through an air shower to remove dust hints at the rigorous quality control measures which have merited the Tahara plant the status as the top auto manufacturing facility in Japan. With its super high-speed and super high-tolerance machine shop, the plant produces parts for the Lexus GS, IS, LS460 and 600h. Quality control is accomplished with an advanced computerized optical inspection system.

Naysayers who would complain that the Lexus brand is merely "souped up Toyotas," would quickly change their tune after a tour to observe the cutting-edge robotics, laser welding, and 6-layer paint application. As a result of such attention to detail, tolerances in door, trunk and hood alignments have been narrowed to 0.2 mm. Over 1,300 photos are taken of the vehicle which are inspected by computer.

With a microphone installed in the car to measure noise levels as the vehicle is run on an outside track, accelerating stopping, and turning. Other performance parameters are measured on a 2.5 mile oval track to measure brake, transmission, and road noise. Potential problems are flagged for human evaluators to check and adjust. No wonder J.D. Power and Associates have called the Tahara plant the best auto manufacturing facility in the world.