At the end of February, when NUMMI workers knew they only had a few weeks left, a surprise audit confirmed that quality had not eroded.
Toyota inspectors checked 100 vehicles, split evenly between Corolla passenger cars and Tacoma trucks, said David Karlin, a quality control team leader on the Tacoma truck line.
The audit found that the Corollas had 0.1 defects per 100 vehicles and the Tacomas had 0.16 defects per 100, Karlin said. The goal was 0.2 defects per 100 vehicles.
"That was an awesome result," Karlin said. "The quality is still there."
Rich Castaneda, a San Jose resident who works in quality control on the Corolla at NUMMI, recalls the differences between his years at the Ford plant in Milpitas and at the NUMMI factory.
"The quality is so much better at NUMMI," he said. "At Ford, you did only one job unless somebody quit or retired. At NUMMI, I was taught five or six jobs."
Perhaps NUMMI was a victim of its own success. Toyota learned so much from the plant about how to manufacture in North America, that over the decades it became a less essential cog for the automaker.
"NUMMI just lived past its useful life," Cole said. "The real curse was the overcapacity. NUMMI had old capacity, and old capacity is always more vulnerable."