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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: Honda Grace hybrid goes on sale in Japan, Daimler spends 100M euros on batteries

The Mercedes-Benz S-500 Plug-In Hybrid has earned an Environmental Certificate from the TUV Sud technical inspection authority. The award is based on a lifecycle assessment of the vehicle. This includes the ability to reduce CO2 emissions by 43 percent through charging, and by 56 percent if charged using hydroelectricity. Read more in the press release below. Daimler is expanding its production capacity for lithium-ion batteries. The company is investing around 100 million euros in its subsidiary Deutsche ACCUmotive, who will provide batteries for the electric Smart Fortwo and Forfour, as well as various Mercedes-Benz models. By the end of the construction, Deutsche ACCUmotive will have quadrupled production and logistics space since 2011. Read more in the press release below. Honda has begun sales of its Grace hybrid sedan in Japan. The Grace is based on the Honda Fit and uses the automaker's Sport Hybrid i-DCD system. It comes in front- and four-wheel-drive versions and uses a seven-speed DCT with built-in motor. The Honda Grace starts at the equivalent of about $16,500. Read more in the press release below. Honda has begun operation of its wind farm in Brazil. The farm consists of nine wind turbines, expected to produce about 95,000 MWh of electricity per year, which is on par with Honda's consumption for automobile production in the country. Honda is aiming to cut its CO2 production by 30 percent by 2020 compared to 2000 levels. Read more in the press release below. Toyota has won the 2014 World Endurance Championship's Driver and Manufacturer categories with hybrid technology. Toyota celebrated the win after the final race in Sao Paolo, Brazil. Toyota uses the same hybrid technology in its racing cars as it does in its production vehicles. Read more in the press release below. Controlled Power Technologies and other groups are calling for an international 48-volt electrical standard for vehicles. The groups called for the standard at the International Conference Automotive 48 V Power Supply Systems, saying that the 48V standard for mild hybrids would help make the systems more affordable. This will make it easier for automakers to meet the more stringent CO2 standards anticipated in coming years along with the introduction of the World Light vehicles Test Procedures. Read more at Green Car Congress. The world's first certified three-litre luxury saloon: S 500 PLUG-IN HYBRID receives Environmental Certificate Stuttgart.

Here's the 2017 Toyota 86: Don't call it a Scion

After we heard the bells toll for Scion yesterday, we told you that the Scion FR-S will transform into a Toyota. That's right: just a rebadging. The practical question is, which badge? The philosophical question, which we can't answer yet, is where it'll sit in the pantheon of front-engined, rear-drive Toyota sports cars, of which the Supra was the last one to visit our shores, from 1992 until 1998 in its fourth generation. And as if summoned by this conversation, this camouflaged prototype appeared. Our best guess is that this is going to be the US-bound, Toyota-badged version of the Subaru BRZ and all the other 86-badged variants: the Toyota 86 (in Asia, Australia, New Zealand, South America, and South Africa), Toyota GT86 (in Europe and New Zealand again), and Toyota FT86 (in Nicaragua and Jamaica). For simplicity's sake, let's call it a Toyota 86. Peer into the 86's swirly camo, and it looks like the car is going in for a light refresh. The lower intake in the front fascia, if it's representative of a production part, adopts a different shape and is considerably wider and narrower than either the BRZ or FR-S units. It also appears that the turn signal and its surround are reshaped, different than any of the current variants. Changes out back appear mild. The area around the license plate seems to be smoother, and there is likely a predictable light restyle of the bumper skin and defuser under the camo. We don't expect a significant power increase, and certainly not a turbocharger (sorry!), but crossing fingers wouldn't do any harm. Related Video: