Toyota's assembly and components plants in the United States and Canada are expected to go back to work on May 4, along with much of the rest of the industry. But it will be a long, slow slog before the inventor of the Toyota Production System gets close to anything nearing a normal run rate.
"This is more of an opening day," cautioned Chris Reynolds, head of manufacturing for Toyota Motor North America. While the automaker has sufficient stores of parts on hand to start building vehicles once workers return to plants, Reynolds said Toyota would take time "to shake off the rust" with workers who haven't been on the job in more than a month, and to implement and train workers in extensive new safety procedures that will both slow the run rates of assembly lines and hopefully help keep them safe.
"I would be surprised if a car rolls off a line anywhere on May 4," Reynolds told reporters on a conference call Thursday. The new procedures — including staggering entr…