Toyota faced acceleration issues caused by floor mats trapping pedals and pedals binding under hard acceleration, resulting in crashes and deaths. This led Toyota to recall over 5 million vehicles and implement short term solutions like cutting pedal edges. Toyota proposed long term solutions like having a single supplier for each pedal model to better control quality, designing custom floor mats for different vehicle types, and implementing an electronic throttle override system.

3.  Acceleration issues
caused by pedals
being entrapped
by floor mats and
the pedals
themselves binding
under hard
acceleration.
 Floors mats were
standard and did
not fit across all
Toyota models

4.  Speed crashes and
deaths
 Must recall 5 million
cars

5.  Pedals being too big
 Chopping the edge
of the bottom of the
pedals
 This is only a short
term solution

7.  Second recall, affecting nearly three
million vehicles
 Denso vs CTS
 Short term solution
 Failure of brand loyalty

9.  Create a stronger and more hands on
relationship with our suppliers.
 To ensure that the product between
both suppliers are as similar as possible.
 Have only one supplier of pedals to a
model to better control consistency of
the product line.

10.  Help ensure quality in
a particular model
 An easier
identification of parts
needed per model
 Better organize
method of recalling
vehicles if future
problems were to
occur

11. Denso CTS Corporation
 Yaris  Prius
 Corolla  Venza
 Matrix  Avaion
 Camry  Rav4
 4Runner  F J Cruiser
 Sequoia  Sienna
 Land Cruiser  Highlander
 Tundra  Tacoma

12.  Halt the
implementation of
pre-existing luxury
floor mats across
models
 Engage design
teams with the task
of creating separate
floor mats for SUVs
and cars

13.  Shift our already collaborative emphasis
to a design for failure mindset
› E.g. if we had implemented an overriding
throttle-by-wire system as even the Big 3 had
done, we could have averted both recalls
 Overriding Throttle-by-Wire System: when
gas injection to engine is electronically
shut off when brakes are pushed

14.  While the short-term costs of designing
more customized floor mats and
implementing a new design feature are
substantial, they are small compared to
the long-term savings garnered from...
1. Legal liability
2. Brand diminishment
3. Large-scale recall
 External Cost of Quality Features