Toyota is considering a major expansion of robotics across its global manufacturing operations, with an estimated requirement for approximately 400,000 robots. The initiative would involve both new installations and the replacement of existing equipment, including conventional industrial robots and newer humanoid systems. The Japanese automaker is also developing robots capable of learning manufacturing tasks from human demonstrations, with the aim of transferring those skills between factories.
The plans point to a substantial investment in factory automation. Toyota estimates that modernising its manufacturing operations could require annual expenditure of around ¥1 trillion from 2028. However, the company has not made a definitive commitment to that level of spending or established how long the investment programme would continue.
Factory modernisation and physical AI
The proposed programme covers Toyota, its group companies and major suppliers. The company intends to modernise approximately 60 factories worldwide and upgrade a robotics fleet comprising around 150,000 units at Toyota and group companies and another 250,000 at suppliers. The investments would cover factory infrastructure as well as robotics and other automation technologies.
The 400,000 figure does not represent a confirmed order for humanoid robots. Although some reports have described the initiative in those terms, the total includes both humanoid and non-humanoid systems, as well as replacements for existing machinery and new installations. Toyota has not disclosed how many humanoids it ultimately intends to deploy.
Toyota’s plans also extend beyond installing additional machines. The company wants to connect factories, production equipment and robots through a shared digital infrastructure, enabling production data and robot capabilities to be exchanged across its manufacturing network. It refers to this approach as Factory Automation 3.0.
ELEY demonstrates learning from human workers
One of the technologies Toyota is developing for this transition is ELEY, a robot designed to learn physical tasks from human demonstrations. Developed using large behaviour models from the Toyota Research Institute, ELEY is intended to acquire manipulation skills that can subsequently be performed autonomously.
Unlike bipedal humanoid robots, ELEY moves on wheels. It weighs approximately 50 kilograms and has two arms equipped with two-fingered grippers. Its potential applications include handling components and performing manipulation tasks that require more flexibility than conventional industrial automation.
During a recent technology demonstration in Europe, Toyota showed ELEY folding a T-shirt after learning the task from human demonstrations. According to Japanese media reports, the robot underwent approximately 1,500 training repetitions over two weeks before performing the task autonomously. The demonstration illustrated its learning capabilities rather than a production-ready automotive assembly application.
Toyota aims to use its manufacturing network to collect training data from experienced workers. The company has approximately 18,000 skilled production specialists, known as takumi, whose knowledge could contribute to teaching robots complex manufacturing operations. Skills acquired at one location could eventually be shared with robots at other factories.
Robots working alongside people
Toyota is positioning the initiative as a way to address labour shortages, modernise ageing production facilities and improve manufacturing productivity. Rather than focusing exclusively on replacing human workers, the company is developing systems that can operate alongside employees and potentially assist in training new staff.
Its broader robotics strategy combines physical AI with the Toyota Production System, which emphasises continuous improvement and the reduction of waste. By connecting robot learning with production data, Toyota wants to make automation more adaptable to different manufacturing tasks.
The company has already begun testing robotics applications for parts transportation and picking. Toyota has identified these factory applications as demonstration projects and outlined plans to expand robotics into activities outside automotive manufacturing, including medical equipment transportation.
Automakers expand robotics programmes
Toyota’s plans come as other automotive manufacturers increase their investments in robotics and physical AI.
Hyundai, which owns Boston Dynamics, has announced plans to introduce humanoid robots at its manufacturing operations in Georgia, United States, beginning in 2028. The automotive sector is increasingly exploring how robots capable of learning and adapting to different tasks could complement existing industrial automation systems.
For Toyota, the proposed programme would combine conventional factory upgrades with the introduction of more adaptable robots. Its existing manufacturing infrastructure and production workforce would provide an environment for collecting data and developing robot capabilities.
The company has not yet confirmed a final investment commitment, a deployment timetable for all 400,000 robots or the proportion that will use humanoid designs. The figure should therefore be understood as an estimated requirement for a broader factory modernisation programme rather than a confirmed humanoid robot order.
