they have a commercial here in us for toyota,that they are investing 1 million $ every hour for our safety. the first thing came to my mind is damn your wasting too much money !
Toyota, just like all other manufacturers including your (as in the population of this board's) beloved perfect can do no wrong BMW, produce automobiles. They do not produce parts of automobiles. Other manufacturers produce the parts and sell to Toyota.
Toyota is now coming into scrutiny because back around 2005ish or so, maybe earlier, the CEO was recorded and shown on the news here in the US stating that they need to start cutting costs.
I am guessing that due to the legendary reliability and dependability history of Toyota, they do not know how to cut costs in the bits and pieces that they use to assemble their cars. They have already streamlined the process with stuff like FIFO, Lean Manufacturing, and all the other buzz words that the parts manufacturers try to pick up on from Toyota.
Toyota, just like every other manufacturer, takes quotes from their parts suppliers. They supply the general design and the supplier bids for the parts. Toyota then approves or disapproves the quote, supplier builds the tooling or part, submits a capability study, and is awarded the job or not. There is more than one supplier doing this in which it is up to the vehicle manufacturer to chose the quality of supplier vs. cost. Many manufacturers go with the lowest quote, thus many times the lowest quality. Toyota has a history with top quality and that sounds like it changed since the turn of the century.
You will be happy to know that your beloved BMW will share some parts suppliers with Toyota. BMW will also share some parts suppliers with your hated " crappy American" manufacturers as well. I know, I've worked for one of those parts suppliers for 15 years, 6 of them in the quality department and 9 of them in the Research, Development, and Technology department.
It all boils down to cost vs. quality. When process improvement is nearly plateaued, cost reduction will start into the quality sector. Toyota is top dog in the auto manufacturer, and now wants to become even bigger. The only thing left for them to do in combating cost is to move on to messing with parts supply quality.