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Toyota Motor Manufacturing Texas Vice President of Manufacturing Susann Kazunas, left, and San Antonio Manufacturers Association CEO Dan Yoxall pose for a photo during the automaker’s ceremony for the launch of the redesigned 2023 Sequoia SUV.
The new Sequoia on display during the ceremony at Toyota’s South Side plant. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Vice President of Manufacturing at Toyota Motor Manufacturing Texas Susann Kazunas speaks during the Toyota’s line-off ceremony of the Sequoia at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Toyota workers clap during the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Vice President of Manufacturing at Toyota Motor Manufacturing Texas Susann Kazunas speaks during the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Toyota Texas President Kevin Voelkel speaks during the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Bexar County Judge Nelson Wolff speaks during the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
San Antonio Major Ron Nirenberg speaks during the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Rep. John Lujan speaks during the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
People take photos of the new Sequoia at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
People film on their phones during the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Toyota Texas President Kevin Voelkel joins the Toyota team in an end of meeting cheer during the line-off ceremony of the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022.
People hold up custom made signs during the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022.
San Antonio Ron Nirenberg is seen during the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022.
People chat before the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Manolo Rodriguez checks out the new Sequoia at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Attendees mill about during the Toyota’s line-off ceremony of their latest vehicle, the Sequoia, at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Attendees check out the new Sequoia during the line-off ceremony of the vehicle at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Attendees, including Councilman Clayton Perry, left, check out the new Sequoia during the line-off ceremony of the vehicle at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Attendees check out the new Sequoia during the line-off ceremony of the vehicle at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 21, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant. Toyota spent $391 million upgrading the plant to be able to manufacture the Sequoia.
Toyota’s redesigned Sequoia is being unveiled Wednesday at Toyota Motor Manufacturing Texas in San Antonio. The Express-News got a preview of the big SUV on Tuesday.
Toyota’s latest vehicle, the Sequoia, is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
Vice President of Manufacturing at Toyota Motor Manufacturing Texas Susann Kazunas with the new Sequoia.
Toyota’s latest vehicle, the Sequoia, is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
Toyota’s latest vehicle, the Sequoia, is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
Toyota’s latest vehicle, the Sequoia, is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
Toyota’s latest vehicle, the Sequoia, is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
Toyota’s latest vehicle, the Sequoia, is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
Toyota’s latest vehicle, the Sequoia, is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
Vice President of Manufacturing at Toyota Motor Manufacturing Texas Susann Kazunas is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
Vice President of Manufacturing at Toyota Motor Manufacturing Texas Susann Kazunas is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
Vice President of Manufacturing at Toyota Motor Manufacturing Texas Susann Kazunas is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
Vice President of Manufacturing at Toyota Motor Manufacturing Texas Susann Kazunas is pictured at Toyota Motor Manufacturing Texas in San Antonio in TX, on Sept. 20, 2022. The Sequoia will be joining the lineup of Toyota vehicles made in the San Antonio plant.
SAN ANTONIO — Toyota on Wednesday began rolling its new hybrid Sequoia SUV off the production line at its plant on the South Side, capping a nearly three year, $400 million transformation of the complex and marking a new era for the automaker in San Antonio.
The 2023 Sequoia is the first new model of the full-size SUV since 2008. Toyota shifted production of the vehicle to San Antonio from Indiana to build it alongside the redesigned Tundra pickup, which began rolling off the line in December . The two vehicles are built on the same big-bodied platform.
“Every time you see a Sequoia or Tundra on the road, I hope you feel the same sense of pride that I feel knowing that these trucks were born in Texas and built by Texans,” Kevin Voelkel, president of Toyota Motor Manufacturing Texas, said to a crowd of a few hundred gathered at the plant Wednesday.
Toyota, the world’s top-selling automaker, spent $391 million since 2019 to increase the plant’s footprint by 147,000 square feet and retool production lines to pump out the new Tundra and Sequoia. The plant has the capacity to build as many as 200,000 vehicles each year.
On ExpressNews.com: Production of new Sequoia, Tundra comes to South Side, marking a new era for Toyota in San Antonio
The Express-News got an early look at the redesigned Sequoia on Tuesday. Powered by a twin-turbo V6, it is being offered only as a hybrid. The basic model base price is $58,300, with the TRD Pro and more luxurious Capstone models starting at $77,000. For comparison, car buyers in August paid $73,646 on average for a new full-size SUV, up 9 percent from a year earlier, according to Kelley Blue Book.
The Sequoia’s engine has 437 horsepower and gets a combined 22 mpg, Toyota says, up from 14 mpg in the previous model. The basic Sequoia features an 8-inch touch screen on the center console and the premium models have a 14-inch screen.
To make room for production of the Sequoia in San Antonio, the company last year moved manufacturing of the Tacoma pickup to Tijuana, Mexico.
The plant also added new workers as Toyota introduced production of the Sequoia, which requires more components than the Tacoma. The factory employs 3,800 employees — up from about 3,000 before the pandemic — and 23 on-site suppliers employ another 5,100 people in the region. Its investment in San Antonio totals more than $3.1 billion.
“The synergy created by Toyota’s presence has brought an important network of jobs and economic activity,” Mayor Ron Nirenberg said. “Toyota’s investment in our community creates life changing opportunities for our residents.”
The on-site suppliers count on dozens of other companies for components, so the supply chain web for the Tundra and Sequoia includes thousands of different entities, said Jason Reyes, president of Reyes Automotive Group. His company uses molding machines to make plastic parts for Toyota.
“Every hour we’re shipping parts to go directly onto a vehicle,” he said. “So the pressure and synchronization and skill to be able to get that together is absolutely mind-boggling.”
On ExpressNews.com: New Teijin plant in Seguin making beds for Toyota Tundra as automotive expansion in region continues
Supply snarls stemming from the pandemic have bedeviled Toyota and virtually every other automaker in the past 18 months. In early 2021, Toyota had to slow production of the Tundra because of a scarcity of computer chips that enable the vehicle’s electronics. The automaker again temporarily cut production in half at the start of this year because of shortages.
But the roll-out of the Sequoia wasn’t slowed much by supply shortages, said Susann Kazunas, vice president of manufacturing at the San Antonio plant.
“The Sequoia and the Tundra have a lot of shared DNA, which is one of the primary reasons we’re building the full-size truck and full-size SUV” in San Antonio, she said. “The shared components, that has helped us tremendously with many of those potential concerns. From the instrument panel forward, there are a lot of common parts.”
Toyota spent nearly three years upgrading the plant since announcing its $391 million investment into the facility. In addition to installing automated technology such as sensors to detect defects on the line, Toyota had to accommodate the Sequoia’s longer cabin by modifying the “skillets” and overhead chain conveyors that transport the SUVs and pickup trucks through the factory.
Toyota boosted the Sequoia’s fuel economy by using lighter-weight materials such as aluminum and ultra high-strength steel, Kazunas said. And parts suppliers have done the same; a new factory in Seguin owned by supplier Teijin makes bed liners for the updated Tundra using a new plastic composite rather than steel.
Toyota’s investment into the plant “allowed us to do the expansion and assembly shop, and then to prepare the Tundra to be able to integrate an SUV by making some of those modifications early on,” Kazunas said. “A lot of investment into new processes for new materials.”
Sales of the Sequoia have been far behind its peers in the full-size SUV segment. In 2021, Toyota sold 8,070 Sequoias . Meanwhile, the Chevrolet Tahoe saw sales of 106,000 units and Ford sold nearly 82,000 Expedition SUVs last year.
Kazunas wouldn’t say how building the Sequoia in San Antonio may affect sales. But in County Judge Nelson Wolff’s 2008 book “Transforming San Antonio,” which details local leaders’ efforts to land the Toyota plant in the early aughts, he wrote that the automaker picked San Antonio in part because its marketing department thought it would be smart to build the trucks in the country’s largest pickup market.
Kazunas suggested the Sequoia is also a good “fit” with Texas.
“This idea that everything is bigger in Texas — those two things fit in here,” Kazunas said.
In his book, Wolff described how Toyota nearly decided to build the factory in Arkansas. But since Toyota opened the plant in 2003, the region’s automotive industry has boomed. Manufacturers in the metro area have added more than 7,000 jobs in the last five years, according to the Federal Reserve Bank of Dallas.
On ExpressNews.com: Driving force: San Antonio picks up speed in auto industry
The commercial truck and bus manufacturer Navistar International in March unveiled its recently completed, high-tech truck factory on the far South side that produces diesel and heavy-duty electric trucks. Transmission maker Aisin AW completed work on a $400 million plant in Cibolo last fall in connection with the Toyota expansion. And equipment manufacturers have been increasingly setting up shop in nearby Seguin , where Caterpillar has operated an engine factory for over a decade.
“It was a shock to many in the industry when Toyota came here. But they understood Texas was a big market, they understood we have a good workforce, low cost of living and great land,” Wolff said Wednesday. “None of this would’ve occurred without Toyota making the decision to come here.”
Diego Mendoza-Moyers is a business reporter covering energy, manufacturing and labor. A native of El Paso, he has previously written for the Albany Times Union, Las Vegas Review-Journal and Arizona Republic. He graduated from Arizona State University with a B.A. in journalism. Call Diego at 210-250-3165 or email diego.mendoza-moyers@express-news.net