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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."

Toyota's Bob Carter says seat heater stop-sale due to inconsequential compliance error

Last week, Toyota let it be known that a number of its more-popular vehicles were subject to a "stop-sale" order due to faulty seat heaters on these vehicles. No injuries were reported, but the problem affected a lot of models, including the 2013 and 2014 Camry, Camry Hybrid, Avalon, Avalon Hybrid, Sienna, Corolla, Tacoma and Tundra. Toyota originally said 50,000 vehicles were involved, but Bob Carter, senior vice president of automotive operations for Toyota Motor Sales, knocked that down to 30,000 during an interview at the Chicago Auto Show this week and said that the problem is not going to have a big impact on Toyota's sales. "It's an important situation but it will have a very minor impact on February sales," he told AutoblogGreen. "Dealers will start receiving new heating elements this week and then we have a process to take out the heating element that was put in and exchange that for the new fabric. It's very simple. It's a quick repair." Quick in this situation means about three hours to swap out the heating elements in two seats, according to Toyota's John Hanson. Since the Avalon also has heated rear seats, that car will require a total of six hours in the shop. Hanson said there was no official timeline for when the exchange program would be completed, "but new vehicles are arriving at some dealerships with the new seat heaters already installed." With a fix already in place, Carter would not comment on whether a recall is likely, saying only, "I'm not the expert on that. We're working with the NHTSA and ultimately it's their decision. We believe it's an inconsequential compliance error that was made by one of our suppliers and we're going to correct it." Featured Gallery 2013 Toyota Camry Hybrid: Review View 23 Photos News Source: Toyota Green Chicago Auto Show Toyota AutoblogGreen Exclusive Hybrid camry hybrid bob carter

2014 Toyota FJ Cruiser Ultimate Edition

Introduced at the end of 2006, this is the last year for the Toyota FJ Cruiser, the reincarnated FJ40-series Land Cruiser that will shortly journey to Takama-ga-hara, the Plain of High Heaven. In its first model year, we drove it to SEMA and found it, shall we say, coarse. It bobbled on the freeway and droned in the cabin, its boxy interior providing four bounce-boards for unpleasant frequencies. Tall mirrors helped one work around the eclipse of vision aft of the B-pillars, but navigating traffic required forethought and technique. Its turning circle was measured in kilometers. For the first two years of its life, it needed premium gas. It may have been fun to look at, but we couldn't wait to get out of it.
That's not the case anymore, and now the FJ Cruiser is poised to join a long list of vehicles that got better and better, then got axed.
Driving Notes