The Secret Sauce to Mazda’s Indestructibility

The rush to come up with a viable and reliable automobile at the beginning of the 20th century can be equated to today’s clamor for who will successfully make travel to outer space practical and reliable. In the 1920s, Ford created a dependable and efficient roadmap for car production, becoming one of the most successful automakers at the time.

At the same time, in Japan, little-known Mazda, then Toyo Kogyo Co., Ltd, was transitioning from cork manufacturing to vehicle manufacturing. The two brands would later collaborate in one of the benchmark supportive partnerships in automotive history. While not as popular as Japanese rivals like Toyota, Mazda is famous for automotive innovation and a commitment to excellence, visible in their cars. From the idolized Mazda R36, the beloved Miata, and the one-of-a-kind Mazda REPU pickup to the latest premium CX-90 SUV, Mazda has made some exciting and memorable cars over the years.

In an industry that chases economies of scale, Mazda proudly embraces a minimalist approach rooted in traditional Japanese philosophies. Monotsukuri – a key driving force at Mazda, focuses on specialization. Craftsmen are valued, and invested in, to finesse Mazda products over time. The result is a consistent, impressive reliability rating. According to Repair Pal, Mazda’s reliability rating of 4.0 out of 5.0 solidifies its position as the 5th most reliable brand out of 32 rated brands, with an annual repair cost of $462.

Japan is renowned for its automotive success and a strong respect for its culture. Automakers in Japan incorporate Japanese philosophies in their production processes. Toyota emphasizes Jidoka, a philosophy that blends automation with a deep human understanding and control, while Mazda associates with Monotsukuri. In simple terms, Monotsukuri focuses on making things in-house rather than outsourcing.

By doing things yourself, you understand every aspect of the process, and in turn, become a highly skilled specialist. At Mazda, these specialists are called Takumi. With the majority of global companies outsourcing most of their production for scaling and cost-cutting, Mazda produces each car part in-house. This ensures careful attention to detail and efficient quality control. In addition, the automaker deploys modern technologies such as 3D printers, CNC technology, and robotics.

A classic example of Mazda’s success with this philosophy is the rotary engine, which is synonymous with the brand. When the Japanese government was pushing for mergers between automakers to have a globally competitive motoring sector, in the 1950s and 1960s, Mazda was on the brink of being absorbed.

The relatively new and untested rotary engine was assigned to a team of specialized engineers, including the man behind the engine, Felix Wankel. The engineering buffs stood for engineering ingenuity, and the aftermath was Mazda’s first rotary-powered sports car. Though its reliability is highly contentious, Mazda car sales at the time skyrocketed.

While the Monotsukuri model stifles economies of scale, it enables the manufacturing of a few cars that are subjected to high-quality standards. As a result, Mazda is consistently able to produce reliable cars. Another plus is that the assembly can accommodate the production of different models on the same line. This has worked for Mazda most of the time, enabling them to exemplify simplicity and creativity while defying the ordinary.While the Monotsukuri model stifles economies of scale, it enables the manufacturing of a few cars that are subjected to high-quality standards. As a result, Mazda is consistently able to produce reliable cars. Another plus is that the assembly can accommodate the production of different models on the same line. This has worked for Mazda most of the time, enabling them to exemplify simplicity and creativity while defying the ordinary.

Photo Source: Mazda Newsroom