Toyota Motor estimates that expanding automation across its factories, group companies, and major suppliers could require around 400,000 robots and annual spending of about 1 trillion yen ($6.4 billion) from 2028.

The potential investment was discussed with investors earlier in September, according to Reuters. Toyota has not said whether the full investment will proceed or how many years spending at that level would continue.

The 400,000 figure includes replacements for existing machines and new robot installations, covering humanoid and non-humanoid systems. The potential investment spans industrial robots, automated logistics, and future human-robot collaboration on factory floors.

Toyota already uses and tests robotics across several manufacturing processes. In its FY2026 financial results, the company listed factory demonstrations involving parts transportation and parts picking, alongside robotics work in areas such as medical equipment transportation.

At Toyota’s Kamigo Plant, a piston assembly line that began operating with robots in January 2025 has since moved from three operators to full automation, according to Toyota’s 2025 integrated report.

The plant’s automation work began much earlier. It started introducing robots on selected sub-lines in 2008, but the company later encountered maintenance constraints as it expanded engine production overseas.

Toyota said some overseas facilities lacked enough skilled maintenance workers to support the automated equipment. Some processes were consequently returned to manual production while manufacturing knowledge from Japanese plants was transferred to overseas sites.

Workers then developed jigs and tools that Toyota said could double or triple efficiency in some manually operated processes. Knowledge accumulated through that work was later used in the development of newer automated production systems, including the piston assembly line at Kamigo.

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