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Five automakers now being investigated by NHTSA for airbag woes

It appears that Toyota's renotification to owners of recalled vehicles from last year is just the tip of the iceberg for what could potentially be a much larger industry-wide recall. The National Highway Traffic Safety Administration is opening a preliminary evaluation investigation into roughly 1.1 million vehicles from Chrysler, Honda, Mazda, Nissan, Toyota and parts supplier Takata regarding faulty airbag inflators in several models.
NHTSA has received six reports - three directly, two from Takata and one from Toyota - of vehicles with ruptured airbag inflators from 2002-2006, which resulted in three injuries. So far, all six incidents have occurred in high humidity areas like Florida and Puerto Rico. According to Toyota's latest recall announcement, the inflators may have an improper propellant that could cause it to rupture in a crash and the bag to deploy abnormally.
This new investigation follows a previous recall from April 2013 of about 3.4 million vehicles worldwide for the airbag inflators from Takata. As Autoblog reported, Toyota jumpstarted the new situation when it found that the original list of serial numbers for the faulty part was incomplete and discovered more cars in need of replacement. Honda and Nissan told us that they were investigating whether further models would need called in again as well. Mazda told Autoblog: "Regarding the current Takata situation, we're working closely with NHTSA and investigating the situation, but nothing else to report at this time." Chrysler Group responded to us with the statement: "Chrysler Group engineers are conducting the appropriate analysis. The Company will cooperate fully with the National Highway Traffic Administration."

Honda's Acura NSX masterstroke: building the factory in Ohio

When Honda announced it was going to build its NSX supercar in Ohio instead of Japan, it caught everybody in the industry by surprise. No one expected this proud Japanese company to build its most technologically advanced sports car anywhere but in its home country. Now Honda has a supercar production facility in rural Ohio that would be the envy of any Formula One team. The people at Honda call it the PMC, but its official name is the Performance Manufacturing Center. It's a building that started out as a shipping facility for suppliers, but Honda invested $70 million to transform it into a showcase facility that will build the NSX. Honda benchmarked the assembly operations at Ferrari, Lamborghini, McLaren, and Bentley before work began on its facility. The 200,000 square-foot building will also double as a customer reception center – Honda will open the doors for customers to come see their car being built. It's also going to offer them high-speed test drives at the gigantic Transportation Research Center just down the road. No one expected this proud Japanese company to build its most technologically advanced sports car anywhere but in its home country. Inside, the layout is wide open and well lit. There are no stripes or lines on the floor and none of the different departments are walled off. This creates a more welcoming appearance and lets you get a comprehensive view of the entire process at a glance. And with an eye towards future lessons learned, most of the equipment is of a modular design that can be easily reconfigured or moved. The body shop and paint shop are enclosed by glass walls so that anyone can see what's going on inside. And while you'll see some automation here and there, the idea was to achieve a blend between man and machine, not to try and automate everything. This is a low-volume facility with production targeted at only eight to ten cars a day. The plant runs four days a week with one ten-hour shift. Don't expect to see rows of new NSXs parked on any dealer's lot. The car will only be built to order. Honda is obsessed with ensuring the NSX is built to the most exacting quality standards. The plant people pored over the JD Power Appeal study to determine what supercar customers care about the most, then looked at which aspects of that directly tie into manufacturing. They developed their quality control strategy with three goals in mind. First, they wanted to build everything right the first time with no adjustments.

Recharge Wrap-up: VW exec predicts EVs with 375-mile range

Volkswagen says EV ranges over 300 miles aren't too far in the future. Plug-in hybrids are merely a bridge to all-electric mobility becoming more practical for people who need to travel longer distances, according to Dr. Heinz-Jakob Neusser, Volkswagen's head of powertrain development. Energy density is increasing rapidly in new batteries. Speaking about the e-Golf, Neusser says, "I expect the next generation in 2015-17 will increase to around 300 km [186 miles] and the following step will be around 500-600 km [310-372 miles]." Neusser also says he believes that charging infrastructure will improve to catch up with these more advanced batteries. Read more at Motoring. BMW is offering higher incentives for the all-electric i3 than the range-extended version. More buyers are opting for the i3 REx, with its 78 extra miles of range. So, to move the standard i3 (which is already cheaper), BMW is offering $2,000 in incentives for October - double what is offered for the i3 REx. The added incentives help close the price gap between the BMW and other EVs with similar ranges. The deals won't last long, though. According to New Jersey BMW salesman Manny Antunes, BMW's current incentives are "as aggressive as they're going to get" for a while. Read more at Green Car Reports. Honda is changing its research and development process for all cars after a series of Fit Hybrid recalls. The hybrid version, which makes up more than half of all Fit sales in Japan, was the subject of four recalls within nine months. In response, Honda will change the way it develops cars worldwide, with one extra "gate" to pass in the process. Honda will do prototype testing earlier in the research process to see how separately developed components work together before moving onto the car's development phase. It will add time and cost to making cars, but Honda hopes it will help prevent problems - like those that come with a flurry of recalls - down the road. Read more at Automotive News. Featured Gallery 2015 Honda Fit Hybrid View 16 Photos Related Gallery 2014 Volkswagen e-Golf: Frankfurt 2013 View 15 Photos Related Gallery 2014 BMW i3: First Drive View 33 Photos News Source: Motoring, Green Car Reports, Automotive NewsImage Credit: Honda Green Plants/Manufacturing BMW Honda Volkswagen Electric Hybrid recharge wrapup