Mazda is preparing to roll out its own electric vehicles (EVs) from 2027 using a flexible production system at its Hofu 2 plant in Japan, moving away from dedicated EV manufacturing lines favored by some rivals.
The automaker, which has faced criticism for a slow introduction of compelling EV models, currently sells its EZ-6 sedan and EZ-60 SUV mainly in China and Europe, both based on Chinese designs. However, Mazda’s new EV lineup will be developed independently and produced alongside existing hybrid, gasoline, diesel, and plug-in hybrid vehicles.
Mazda officials told AutoNews that this mixed production system will reduce investment costs by about 85% and cut production lead times by 80%. Taketo Hironaka, managing executive officer overseeing production engineering, said the approach allows the company to maximize capacity utilization and quickly adapt to fluctuating demand.
“A dedicated EV line isn’t necessary because our lines can already accommodate mixed production,” Hironaka said. “This plant is at the cutting edge of Mazda’s manufacturing.”
The Hofu 2 facility currently assembles models including the CX-60, CX-70, CX-80, and CX-90. The plant uses flat pallet platforms that move across the factory floor rather than fixed conveyors, with automatic guided vehicles delivering powertrains regardless of whether the vehicle is an EV, PHEV, diesel, or gasoline model. This setup enables Mazda to extend production lines within seven days, compared to six weeks previously.
Hironaka explained the company’s lean asset strategy aims to maintain near-full capacity utilization while allowing EV production ratios to adjust flexibly according to market demand. “Doing mixed production means our BEV ratio will change according to customer demand at a given time,” he said. “We may see a BEV ratio of 100 percent, or it could be 0 percent. For a small player like us, using our production lines 100 percent by employing mixed production is a smart way to go.”
The efficient manufacturing approach also serves as a buffer against external challenges. Mazda is preparing for the impact of a new 25% U.S. tariff on vehicles and parts, which could affect its sales in a key overseas market.
“The 25 percent figure is outrageous,” Hironaka commented. “We will control what we can. The key is not having any waste in fixed costs and capital investment. In that sense, this Hofu No. 2 plant is a plant that is at the forefront of our approach.”