A tragic explosion at a key supplier has thrown a wrench into Toyota’s manufacturing plans, halting production of the popular RAV4 SUV and Harrier crossover in Japan. The incident, which occurred on March 6, 2025, at Chuo Spring Co.’s facility in Toyota City, claimed one life and left two workers injured, sending shockwaves through Japan’s automotive supply chain. As a result, Toyota has paused operations at multiple plants, raising questions about how long this disruption might last and its potential impact on global markets, including the U.S.
What Happened at Chuo Spring Co.?
The explosion rocked Chuo Spring Co., a vital Toyota supplier specializing in suspension springs and control cables, around 8 a.m. local time. Early reports point to a dust collector as the culprit, though investigations are ongoing to pinpoint the exact cause. Toyota swiftly responded by suspending three production lines across two facilities: one at the Takaoka plant, which builds the RAV4 and Harrier, and two at a Toyota Industries Corp. site also assembling the RAV4. The company plans to reassess the situation on Monday, March 10, but for now, the duration of this halt remains uncertain.
This isn’t the first time Chuo Spring has disrupted Toyota’s operations. In October 2023, a similar explosion at the same plant forced the automaker to idle 13 lines across eight factories for 10 days. That history suggests this latest incident could have a lingering effect, especially given Toyota’s reliance on a just-in-time supply chain—a cost-efficient system that leaves little room for spare parts when emergencies strike.
How Does This Affect Toyota RAV4 Availability?
The RAV4, a global bestseller, is a cornerstone of Toyota’s lineup. Last year, about 21% of RAV4s sold in the U.S. were imported from Japan, including many plug-in hybrid variants. While most U.S.-bound models roll off North American assembly lines, a prolonged shutdown could still tighten supplies, particularly for those Japanese-built units. Toyota has downplayed immediate concerns, stating it’s too early to predict export impacts, but the company is exploring options to offset lost output.
For now, production is paused through at least the first shift on March 10. If the stoppage mirrors the 2023 incident, it could stretch into days or even weeks, depending on the damage assessment and Chuo Spring’s recovery timeline. Meanwhile, the Harrier—an Asian-market sibling to the Venza—faces similar delays, amplifying the ripple effects across Toyota’s portfolio.
A Pattern of Disruptions
Toyota’s supply chain has faced repeated tests in recent years. Beyond the 2023 Chuo Spring explosion, a system glitch in August 2023 brought all 14 of its Japanese plants to a standstill. These incidents highlight vulnerabilities in the automaker’s lean manufacturing model, where efficiency often comes at the cost of resilience. While Toyota has weathered such challenges before, each disruption chips away at production schedules and tests the patience of buyers awaiting their vehicles.
What’s Next for Toyota and the RAV4?
As Toyota evaluates the situation, the focus is on minimizing fallout. The company has hinted at “recovery production” to catch up, but details remain scarce. For U.S. consumers, the impact may be limited unless the halt drags on, given that North American plants supply the bulk of RAV4s stateside. Still, any delay could stoke frustration among buyers already navigating a competitive SUV market.
The 2025 Toyota RAV4 remains a hot commodity, with an all-new version on the horizon. This latest setback, however, underscores the fragility of global supply chains—even for an industry titan like Toyota. For now, all eyes are on March 10, when the automaker will decide its next move.
Pros:
- RAV4’s strong North American production may cushion U.S. supply.
- Toyota’s proactive response signals adaptability.
Cons:
- Uncertain timeline could delay deliveries.
- Repeated incidents expose supply chain risks.
In summary, the explosion at Chuo Spring Co. has sidelined Toyota RAV4 production, with no clear end in sight as of March 9, 2025. While the full scope of the disruption is still unfolding, Toyota’s track record suggests it will rebound—but not without some bumps along the way.
Toyota relies on the Just-in-Time (JIT) system, keeping minimal inventory while maintaining a strict production schedule. But for the second time in six months, an explosion at the Chuo Spring plant has disrupted RAV4 production. Is it time to rethink this strategy?