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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."

Lightweight Toyota GT86 spotted on Nordschleife with carbon panels, upgraded aero

We've seen (and frankly reported on) so many rumors of more powerful and performance-focused versions of the Subaru BRZ, Toyota GT86 and Scion FR-S at this point that haven't materialized that, at this point, we're almost tired of them. Almost. But what we have here was enough to pique our jaded interests as only a carbon-bodied sports car on the Nürburgring could do.
What we're looking at is, well, we don't quite know, to tell you the truth. What we can tell is that it's a Toyota GT86 (Scion FR-S for us) wearing new wheels and a carbon-fiber hood, roof, racing-spec rear wing and subtle lip spoiler. The vents in the hood indicate that the prototype in question could be packing an upgraded engine to go with the lighter body panels and upgraded aero, and the interior (at least as far as we can see) looks pretty well stripped out.
The right-hand drive configuration tells us this is either destined for former territories of the British Empire or for the racetrack. Considering the ride height, full glass and apparent lack of roll cage, our money's on this prototype is being developed for the Japanese Domestic Market, where Toyota badges the sports car simply as the 86. We can always hope, though, that some version makes it into Scion showrooms in North America... we just won't get our hopes up too high.

Ford Fusion production scaled back just 3 months after it was accelerated

Three months after kicking off production of the Ford Fusion at its Flat Rock, MI factory, Ford Motor Company is taking steps to trim output in the face of heavily discounted competition from Toyota and a growing supply of vehicles.
The addition of Fusion production in Flat Rock - which also builds the Mustang - was meant to be what pushed the handsome mid-sizer past its arch-nemesis, the Toyota Camry. An extra facility building Fusions was also meant to curb the growing demand for Ford's highly profitable sedan.
But with word that Flat Rock would take "approximately" one extra week off for the holidays combined with an 88-day supply of Fusions - reportedly due in no small part to what Morgan Stanley analyst Adam Jonas called "aggressive discounting of the Camry" - some analysts are now beginning to wonder if Ford may have overextended itself by adding a second Fusion facility to the mix.