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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."

Recharge Wrap-up: BMW Next 100 video, how Nissan "tops off" battery

BMW explains the ideas behind its Vision Next 100 concept car that debuted at the Geneva Motor Show. As BMW celebrates its 100th birthday, it wants to look into the future rather than dwell on its past. This involves the digital and analog worlds working together "to create a seamless experience." Hence the "live geometry," wherein physical parts of the car move to translate digital information to the driver. The video also gets into the future of driving modes, like "Ease," for more autonomous driving, and "Boost," for when the driver wants to take control to enjoy some motoring the good, old-fashioned way. Check out the video above, and read more from Hybrid Cars. Nissan has managed to find a way to boost the range of EV batteries inspired by pouring a glass of beer. The automaker has found that after a full charge, one can wait a few minutes for subsequent "minicharges" to "top off" the battery. The voltage dips slightly, much as the foam does on a pint of beer, allowing the battery to accept some more juice. The result is an extra 0.7 percent of energy, which could mean just enough extra range to reach the next charging station. Read more from Automotive News. Hyundai has delivered its first Tucson Fuel Cell in Ontario, Canada. The lucky recipient is Joseph Cargnelli, Chief Technology Officer of Hydrogenics Corporation, a company based on hydrogen technology. The expansion into Ontario follows Hyundai's trial of six Tucson Fuel Cell vehicles in the Canadian province of British Columbia. Read more at Green Car Congress. Toyota has entered a public-private partnership to test an end-to-end hydrogen supply chain in Japan. The collaboration with the Kanagawa Prefectural Government, the municipal governments of the cities of Yokohama and Kawasaki and three private companies to create renewable hydrogen to power forklifts. It will use wind energy to electrolyze hydrogen, which will then be shipped to a factory, a vegetable and fruit market and two warehouses to be used in the fuel cell-powered vehicles. This supply chain is expected to reduce CO2 emissions by 80 percent compared to traditionally fueled forklifts. Read more from Toyota. Related Gallery BMW Vision Next 100 Concept News Source: Hybrid Cars, YouTube: BMW, Automotive News, Green Car Congress, Toyota Green BMW Hyundai Nissan Toyota Concept Cars Electric Hydrogen Cars Videos recharge wrapup

Tougher than steel: Wood pulp could make lighter auto parts

KYOTO, Japan — The global push among carmakers to make ever lighter vehicles is leading some auto suppliers in Japan to turn to what seems like an unlikely steel substitute — wood pulp. Japanese researchers and auto component makers say a material made from wood pulp weighs just one-fifth of steel and can be five times stronger. The material - cellulose nanofibers — could become a viable alternative to steel in the decades ahead, they say, although it faces competition from carbon-based materials, and remains a long way from being commercially viable.> Related: Jay Leno drives the Renew cannabis car — hemp you can't dent Reducing the weight of a vehicle will be critical as manufacturers move to bring electric cars into the mainstream. Batteries are an expensive but vital component, so a reduction in car weight will mean fewer batteries will be needed to power the vehicle, saving on costs. "Lightweighting is a constant issue for us," said Masanori Matsushiro, a project manager overseeing body design at Toyota. "But we also have to resolve the issue of high manufacturing costs before we see an increased use of new, lighter-weight materials in mass-volume cars."A NEW PROCESS Researchers at Kyoto University and major parts suppliers such as Denso Corp, Toyota's biggest supplier, and DaikyoNishikawa Corp, are working with plastics incorporated with cellulose nanofibers — made by breaking down wood pulp fibers into several hundredths of a micron (one thousandth of a millimeter). Cellulose nanofibers have been used in a variety of products ranging from ink to transparent displays, but their potential use in cars has been enabled by the "Kyoto Process," under which chemically treated wood fibers are kneaded into plastics while simultaneously being broken down into nanofibers, slashing the cost of production to roughly one-fifth that of other processes. "This is the lowest-cost, highest-performance application for cellulose nanofibers, and that's why we're focusing on its use in auto and aircraft parts," Kyoto University Professor Hiroaki Yano, who is leading the research, told Reuters in an interview. The university, along with auto parts suppliers, are currently developing a prototype car using cellulose nanofiber-based parts to be completed in 2020.