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Recharge Wrap-up: Toyota FCV wears silver, Foxconn's $15K EV, solar power at GM

The Toyota FCV made its North American debut at the 2014 Aspen Ideas Festival, and this time it's not sporting its usual blue sheet metal. This silver paint job shows a bit more contrast. Certain features stand out a bit more, especially the black strip that wraps around the grille and down the sides of the hood to the mirrors. This is the production version of the car's exterior, which will go on sale in California next summer. Toyota also had its Driver Awareness Research Vehicle, DARV 1.5, on display in Aspen. DARV 1.5 uses technology to decrease driver distraction and measure driver behavior to provide a safe driving score. See more of both cars in our image gallery. Taiwan's Hon Hai Precision Industry (also know as FoxConn Technology Group) says it is planning to build electric cars that will cost just $15,000, according to The China Post. The world's largest electronics maker, which assembles mobile devices for Apple, promises that the cars will be highly connected. "When integrated with cloud computing, the Internet, smart traffic and smart cities in the future, people will be able to drive more easily and reduce car accidents more efficiently," says Hon Hai chairman Terry Gou. At a shareholder's meeting, Gou didn't comment on production timing or other details about the cars, nor would he answer questions about possible cooperation with Tesla Motors. Hon Hai made headlines in recent years after a series of employee suicides, which led the company to raise worker wages and install anti-suicide netting on its buildings. EV advocates in Illinois took a 500-mile road trip to help temper range anxiety in potential buyers, says the Chicago Tribune. The demonstration, organized by the Illinois Green Economy Network, meant to show people that they can use electric vehicles to drive long distances without getting stranded with a dead battery. The drive began near Carbondale and traveled to 11 different community colleges with charging stations before terminating in Grayslake. Illinois has about 5,000 registered electric vehicles, and 450 public and private charging stations. General Motors is building three acres of new solar arrays to produce an expected 400,000 kilowatt-hours of renewable energy per year. The new arrays at GM's Swartz Creek processing center and Flint engine plant will be completed this fall, contributing to the company's 38 megawatts of solar power from facilities around the world.

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 SEMA cars include Tundra for Baja and wacky DUB Edition Yaris

Toyota has released the first images of its brigade of concepts for the 2014 SEMA Show, introducing a trio of TRD-fettled off-roaders, a pair of DUB-inspired models, a race-ready pickup and a Sienna minivan with 48 inches worth of subwoofers.
Four of the vehicles being shown by Toyota will take part in the grueling Baja 1000 off-road race. The star of that effort will be a race-prepared Tundra, which will actually be competing from November 12 to 16 in the 47th running of the desert race. It'll be supported by a trio of vehicles, which mimics Toyota's TRD Pro Series production vehicles, with the 4Runner, Tacoma and Tundra all acting as support vehicles.
Each of these vehicles has been fabricated by the off-road specialists at N-Fab and comes loaded down with communications and guidance equipment, additional lights and off-road body modifications.