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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."

Europe on track to buy more PHEVs than hybrids by 2019

LMC Automotive, formerly the forecasting division of J.D. Power & Associates, predicts that plug-in hybrids will sell better than conventional hybrids by 2019. By 2021, it envisions PHEV sales at 600,000 units yearly compared to 325,000 standard hybrid sales, and by 2024 PHEV sales are expected to account for 1.2 million sales every year. Part of LMC's prediction is based on a few factors, such as that it believes "electric-only operation will come to be seen as a true luxury characteristic and will be prized sufficiently to command significant premiums." Certain PHEVs are helped in countries like the UK and The Netherlands by generous incentives or other perks, like avoiding inner London's congestion charge, that allow them to address their price differences compared to standard offerings. And the number of PHEVs on the market will soon eclipse regular hybrids, coming from makers across the spectrum. Volvo has twice recently, and only belatedly, learned of the popularity of PHEVs: in 2013 it had to triple production of the V60 PHEV, and just this month it said demand for its XC90 PHEV is four times expectations. The Porsche Panamera E-Hybrid is outselling the traditional hybrid Panamera by more than seven-to-one. And then there's Mitsubishi Outlander PHEV, Europe's best-selling PHEV with 19,855 units, a volume more than three times larger than the second-best seller. Although LMC sees hybrid growth slowing, they're still doing well. Toyota and Lexus build the top-five selling traditional hybrids in Europe, combining for 72 percent of European sales, with the new Auris and Yaris hybrids alone selling 123,506 units in 2014. For LMC's forecast to come true, Europe will need a spectacular change in buying habits, since the top ten conventional hybrids tallied 175,847 sales in 2014, and the top ten PHEVs rang up 36,138 sales. Featured Gallery 2015 Volvo XC90 T8 View 14 Photos News Source: Automotive News - sub. req. Green Mitsubishi Toyota Volvo Hybrid ev sales hybrid sales toyota auris hybrid toyota yaris hybrid

Toyota offered $146.5 million to build Lexus ES in Kentucky

Toyota posted a media advisory yesterday saying that Akio Toyoda, president of Toyota, and Jim Lentz, CEO of Toyota North America, would be making a production announcement tomorrow in New York City, and Automotive News reports that the automaker will be announcing a plan to domestically produce the Lexus ES. According to the report, numerous plants are competing to build the ES in North America, and the State of Kentucky has offered the automaker up to $146.5 million to build the luxury sedan at the Georgetown, KY assembly plant.
If Georgetown gets the ES, which has been built in Japan since its debut in 1989, it would be built alongside the Toyota Camry, which is somewhat ironic since in our review of the 2013 Lexus ES350, we wrote that this ES finally says "goodbye to its Camry roots." In order to get the whole amount offered, the article states that Toyota would have to invest $531.2 million and hire 570 full-time workers at the plant, which doesn't sound all that unreasonable since the plant would require an additional 50,000 units of annual production, not to mention the fact that the Georgetown facility is already at its capacity for building the Camry.