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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."

Cosworth announces Power Packages for Subaru BRZ, Scion FR-S with up to 380 hp [w/video]

Cosworth stands on the list of the most famous engine tuners in the world with its DFV engine engine dominating Formula One for a time in the '70s. So when it teases plans to take on the FA20 engine from Subaru and Toyota found in the BRZ, Scion FR-S and Toyota GT86 abroad, our interest is indeed piqued. Cosworth is promising to take the 2.0-liter, four-cylinder boxer engine from its current 200 horsepower all the way to 325 hp and even 380 hp in a future track version through a series of staged Power Packages. At the moment, only the first stage is available that takes the mill to a potent 230 hp.
Cosworth says that its new strategy is to offer its upgrades in kits rather than individually so that it can be sure that everything works and fits when owners receive it. The Stage 1 Power Package emphasizes helping the FA20 breathe better and includes a nearly complete replacement for the stock exhaust system. There is a sports exhaust with four-inch, diagonally cut, polished tips and Y-shaped muffler, an overpipe front pipe with a spherical resonator and a new manifold header that is 22 percent lighter the standard unit. In addition to that, the kit comes with a software reflash, low temperature thermostat, Cosworth badge and plaque.
The stage one kit is available now, and stages two and three go on sale later this summer, according to its website. Autoblog contacted Cosworth for pricing information for the kits. We will update this story, if we hear back. The company also released a video showing off the exhaust upgrades. Scroll down to watch it and read the full release, below.

Krafcik says US Gov. shutdown is slowing Oct. auto sales

The government shutdown is eroding consumer confidence in the auto market, says John Krafcik, CEO of Hyundai's US sales unit, and could lower October sales by as much as 10 percent, Automotive News reports. "It's that anxiety that keeps customers, potential buyers, on the sidelines when making a big purchase like an automobile," Krafcik says, adding that industry sales could be off by five to 10 percent in October compared to September.
The fourth quarter, which started October 1, usually consists of increased auto sales as dealerships clear their lots to make room for the next year's models. Leading up to the fourth quarter this year, the auto industry was doing well in the fragile, recovering US economy, although September deliveries decreased by 4.2 percent, due in part to this year's Labor Day sales being recorded for August.
To help its customers, Hyundai announced it is deferring new-car loan and lease payments for furloughed federal workers until they're called back to work and also offering them a three-month payment deferral if they buy a new Hyundai in October. "We have already had requests from over a thousand people to have their payments deferred," Krafcik says.