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Toyota recalls 690,000 Tacoma trucks for rusty leaf springs, fire risk

Toyota has announced that it will be issuing a recall of 690,000 Tacoma pickups from model years 2005 through 2011. The affected vehicles include both the four-wheel-drive model and the two-wheel-drive PreRunner (but not the standard 4x2 pickups), which may have a rather serious problem with their rear suspensions.
In some cases, corrosion and stress could cause one of the three or four leaves in the rear suspension's leaf springs to fracture. While the trucks can still be driven with a broken leaf, Toyota is concerned that it could move out of position and impact other components in the rear of the truck, with a particular focus on the fuel tank. Needless to say, but a piece of metal continuously impacting anything, let alone the fuel tank, is cause for concern.
As of this writing, there have been no reports of crashes, injuries, fires or deaths due to this problem, although that won't stop Toyota from informing all affected customers of the issue. Those 690,000 owners will need to report in to dealers for inspections and, if necessary, repairs.

Toyota recalls 2016 RAV4, RX350, and ES350 for stability failure

The Basics: Toyota will recall 4,170 examples of the 2016 RAV4, 90 units of the 2016 Lexus RX350, and 12,400 units of the 2016 ES350. The Problem: A component in the brake actuator assembly may have damage from a manufacturing error. The actuator controls the anti-lock brakes, traction control, stability control, and other systems. If the part doesn't work properly these safety systems might not activate properly. Accidents/Injuries: Toyota spokesperson Amanda Rice told Autoblog, "Regarding the recent recalls, alleged crashes, injuries, and fatalities are reported in many ways to many different organizations. We are not providing specifics at this time." The Fix: Dealers will check the brake actuator's serial number and will replace it if the part comes from a period when the damage could have happened. If you own one: Toyota will contact affected owners by mail. Related Video: TOYOTA RECALLS CERTAIN 2016 MODEL YEAR RAV4 AND LEXUS RX AND ES VEHICLES TORRANCE, Calif., April 6, 2016 – Toyota Motor Sales, USA, Inc. today announced that it is recalling approximately 4,170 Model Year 2016 Toyota RAV4; approximately 90 Model Year 2016 RX350; and approximately 12,400 Model Year 2016 ES350. The involved vehicles are equipped with a Brake Actuator assembly that enables enhanced brake control functions including the Anti-lock Braking System (ABS), Traction Control (TRAC), and Vehicle Stability Control (VSC), among others. There is a possibility that a component inside the actuator could have been damaged during manufacturing, preventing the actuator from operating properly. This could cause a loss of vehicle stability control, increasing the risk of crash. All known owners of the affected Toyota vehicles will be notified by first class mail. Toyota and Lexus dealers will check the serial number of the Brake Actuator and replace actuators assembled during a specific production period. Information about automotive recalls, including but not limited to the list of involved vehicles, is subject to change over time. For the most up-do-date Safety Recall information on Toyota, Lexus or Scion vehicles, customers should check their vehicle's status by visiting toyota.com/recall and entering the Vehicle Identification Number (VIN). Safety Recall inquiry by individual VIN is also available at the NHTSA site: safercar.gov/vin.

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."