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Toyota retires robots in favor of humans to improve automaking process

Mitsuru Kawai is overseeing a return to the old ways at Toyota factories throughout Japan. Having spent 50 years at the Japanese automaker, Kawai remembers when manual skills were prized at the company and "experienced masters used to be called gods, and they could make anything." Company CEO Akio Toyoda personally chose Kawai to develop programs to teach workers metalcraft such as how to forge a crankshaft from scratch, and 100 workstations that formerly housed machines have been set aside for human training.
The idea is that when employees personally understand the fabrication of components, they will understand how to make better machines. Said Kawai, "To be the master of the machine, you have to have the knowledge and the skills to teach the machine." Lessons learned by the newly skilled workers have led to shorter production lines - in one case, 96percent shorter - improved parts production and less scrap.
Taking time to give workers the knowledge to solve problems instead of merely having them "feed parts into a machine and call somebody for help when it breaks down," Kawai's initiative is akin to that of Toyota's Operations Management Consulting Division, where new managers are given a length of time to finish a project but not given any help - they have to learn on their own. It's not a step back from Toyota's quest to build more than ten million cars a year; it's an effort to make sure that this time they don't sacrifice quality while making the effort. Said Kawai, "We need to become more solid and get back to basics."

Toyota teases 2016 RAV4 Hybrid for New York Auto Show

Toyota is being extremely enigmatic with its tease for the newly announced RAV4 Hybrid. The Japanese automaker merely has a photo of the model's rear end with a visible hybrid badge on it. The only additional into tells us to look forward to the CUV's debut in just a few days at the New York Auto Show on April 2. Thankfully, Toyota's teaser shot does give away a few more details about this new version of the RAV4. The LED taillights on display aren't the regular ones that wrap around the back of the popular crossover. In the current design, the white portion is placed near the middle of the hatch, and there's amber at the corner. Here, the indicator is clear and two strips of lights run towards the center. The automaker has made its plan clear to sell even more crossovers in the near future, and the RAV4 has already been a strong mover for Toyota. The company shifted 267,698 of them in 2014, a year-over-year jump of 22.7 percent. Through February 2015, it has sold 41,767 examples of the CUV, a 25.3-percent improvement over the same period last year. Still, the decision to launch a hybrid version of the RAV4 now is a bit surprising. The US market for the green segment was soft last year, and it hasn't really turned around yet. Although, rumors of Toyota launching a greener variant of its popular CUV have been around for years. At that time, the company said it would monitor market demand, and maybe the people have spoken. Related Video: A new hybrid joins the Toyota family. 2016 RAV4 Hybrid. See it April 2, 12:30 p.m. EDT at the New York International Auto Show. Featured Gallery 2016 Toyota RAV4 Hybrid: Teasers News Source: Toyota Design/Style Green New York Auto Show Toyota Crossover Hybrid 2015 ny auto show toyota rav4 hybrid

Toyota Tells Dealers To Stop Selling Six Models

Toyota has told North American dealers to stop selling six popular models with heated seats because the fabric doesn't meet flammability standards. One soft material beneath the seat covers does not comply with U.S. safety standards, company spokesman John Hanson said. No fires or injuries have been reported, but Toyota can't legally sell cars that don't comply with U.S. safety codes, Hanson said. The company is still totaling how many vehicles are affected, but it will be in the thousands, according to the spokesman. The stop-sale order could mean trouble for Toyota and its dealers because it covers the company's top-selling vehicles. Dealers can no longer sell certain Camry, Avalon, Sienna and Tacoma models from the 2013 and 2014 model years, as well as Corollas and Tundras from 2014. The Camry, for instance, is the top-selling car in the U.S. with more than 408,000 sales last year. It depends on how long the repairs will take. Hanson said the company already has a new material that's being installed at factories and will be put in cars that are on dealer lots. "We don't think it will take long to get the parts and make the changes," Hanson said, without getting more specific. As for vehicles already on the road, Hanson says Toyota has reported the problem to the U.S. National Highway Traffic Safety Administration, which will decide if the sold vehicles should be recalled. A NHTSA spokesman said he would check into the matter. "We don't believe that there is a safety issue here because there have been no reports of any problems," Hanson said. The stop-sale order affects cars and trucks distributed to dealers in the U.S., Canada and Mexico. In addition, some vehicles were exported outside North America, Hanson said. The problem was discovered by safety regulators in South Korea, who disassembled seats and tested individual fabrics, Hanson said. U.S. safety standards require fabrics to resist flames at a certain rate, but the one fabric didn't meet the standard, Hanson said. Toyota spokesman Naoki Sumino in Japan said the affected vehicles were sold since August of 2012, when the fabric supplier was changed. Toyota has been struggling to regain its once sterling reputation for quality after announcing massive recalls over several years, starting in 2009, for a variety of defects including braking, accelerators and floor mats. The company was fined for being slow on recalls, which affected more than 14 million vehicles, and faces lawsuits.