Toyota Boshoku America has inaugurated its first-ever “smart plant” in Hopkinsville, Kentucky, marking a significant milestone in the region’s automotive sector. The facility, which represents a substantial investment of $225 million, officially commenced production in November 2023 and has created 157 new jobs for the local community.
Spanning nearly 355,000 square feet, the advanced manufacturing plant is strategically located a few hundred miles from Toyota’s largest factory in the world, situated in Georgetown, Kentucky. According to company executives, the Hopkinsville operation enhances Toyota Boshoku’s North American network, which is headquartered in nearby Erlanger, Kentucky and employs over 14,000 individuals across North and South America.
Innovative Technology and Job Creation
The Hopkinsville facility utilizes cutting-edge robotics, automation, and data-driven systems to manufacture seat tracks, seat recliners, and other motorized components for Toyota vehicles designed in Tennessee and Canada. The plant’s development was supported by various state and local incentives, including packages from the Kentucky Economic Development Finance Authority. These packages mandate that the facility maintain an average hourly wage of $28.49.
In addition to the financial incentives, the site secured two industrial revenue bonds exceeding $230 million in 2025. Inside the smart plant, a sophisticated array of robotics facilitates the retrieval, transportation, and staging of materials, significantly reducing manual handling compared to traditional manufacturing facilities. This technological advancement not only boosts efficiency but also illustrates that automation does not necessarily lead to job losses.
Company leaders maintain that the plant’s workforce of over 150 employees is evidence of the balance between automation and job creation. As production volumes rise, the facility anticipates expanding its workforce to approximately 230 employees. For context, a nearby Toyota Boshoku facility in Salem, Kentucky, employs close to 1,000 workers.
Strengthening Economic Ties in Kentucky
Parts manufactured at the Hopkinsville plant will be distributed throughout Toyota’s extensive manufacturing network. This includes components for the hybrid version of the world’s best-selling vehicle, the RAV4, which is also produced in Georgetown, Kentucky. Officials assert that the opening of this smart plant further entrenches Toyota’s economic presence in the state, where the company and its suppliers have invested more than $11 billion since 1986.
Looking ahead, Toyota Boshoku is preparing for another substantial investment in U.S. manufacturing, with plans for a new facility in West Virginia. This commitment to growth underscores the company’s ongoing dedication to innovation and job creation within the automotive industry.
