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NHTSA opens safety investigations into Toyota, GM and Honda crossovers

The National Highway Traffic Safety Administration is evidently keeping itself very busy these days, as the federal agency has just announced it is launching or renewing investigations into Toyota, Honda and General Motors crossovers.
2006-2008 model year Toyota RAV4 crossovers are under review for allegations of rear tie-rod rust which can result in failure. NHTSA also said it is probing some 35 complaints about 2005 Honda Pilot models with inappropriate activation of the vehicles' stability control system. The alleged malfunction can cause the vehicles to slow down or stop in bad unsafe situations. At the moment, NHTSA is reviewing a petition regarding the Pilot issue, a move that will determine whether it needs to open a full-blown investigation.
In addition, Saturn Outlook and GMC Acadia three-row crossovers built in 2007-2009 are getting looked at for "loss of low beam headlamp" function. One complainant said the wiring in his Outlook overheated and melted. NHTSA says it has received 415 complaints about the problem and a GM spokesman confirmed that the automaker already started a "Customer Satisfaction Program" in December to address the issue.

Race recap: 2016 Belgian Grand Prix is a dozen angry laps

The calm of the Formula One summer break ended with the tumult of the Belgian Grand Prix. The first two days included unusual tire pressures and grid penalties; Mercedes-AMG Petronas' Lewis Hamilton started 21st because of a 55-place grid penalty for engine and gearbox changes, McLaren's Fernando Alonso started 22nd due to a 60-place penalty for the same offenses. The bedlam rolled right into what was effectively an 11-or 12-lap race. Mercedes driver Nico Rosberg took off from pole and the cameras barely bothered with him until he took the checkered flag 44 laps later. Red Bull's Max Verstappen bogged from second on the grid, got swallowed by Ferrari's Sebastian Vettel and Kimi Raikkonen on the way to Turn 1, then attempted to recover by sticking his Red Bull's nose between Raikkonen's sidepod and the apex at the first corner. Vettel, who didn't see Verstappen, turned into La Source leaving only enough room for Raikkonen. Three cars don't fit in a space for two cars. Vettel spun, Raikkonen and Verstappen clobbered one another and all three drivers had to pit for repairs. Force India's Nico Hulkenberg zig-zagged his way into second ahead of Red Bull's Daniel Ricciardo, Williams' Valtteri Bottas, and Sergio Perez in the second Force India. On Lap 6 Kevin Magnussen lost his Renault at Raidillon at the top of Eau Rouge and flew backward into an enormous crash. Magnussen escaped with just a cut ankle. The Safety Car paraded the field for four laps before officials red flagged the race to repair the barriers. When racing resumed on Lap 10, Rosberg led Ricciardo, Hulkenberg, Alonso, and Hamilton. Ricciardo stayed ahead of Hamilton to keep second place at the end of the race, Hamilton easily got around Alonso and Hulkenberg to lock up third. Hulkenberg – who'd given up second to Ricciardo by pitting during the Safety Car period – earned another career-best fourth position ahead of teammate Perez in fifth, followed by Vettel and Alonso on recovery drives, Bottas, Raikkonen, and Felipe Massa taking 10th in the second Williams. Rosberg reignited his Driver's Championship charge with the victory, closing to nine points of leader Hamilton. We could argue that Hamilton had an equally good day by driving from 21st to third, limiting his loss to only 10 points. About that Verstappen, though... We've seen far more experienced drivers attempt the same move Verstappen made into Turn 1 – Raikkonen on Bottas in Russia in 2015, for instance.

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.