2015 Toyota Corolla S on 2040-cars

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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."

More head-up displays are coming to a dashboard near you

With the exception of Apple products — $1,000 for a freakin' smartphone? — one great thing about tech is you typically get more for your money with each passing year. This is particularly true with automotive tech: Features like driver assists and surround-view cameras that were once exclusively available in luxury vehicles now come standard even on some economy cars. The same thing is slowly happening with head-up displays (HUD). For example, the 10-inch HUD in the 2018 Toyota Camry is one of the largest and best HUDs I've seen in any car. And a big improvement on the much smaller HUD in the latest Toyota Prius. Mazda is another mainstream brand that offers HUDs in several of its vehicles. But instead of embedding expensive components in the dash and using a special windshield, the HUDs in the Mazda3 and Mazda6 use a thin plastic lens that folds down when not in use. MINI has a similar solution, but this low-cost approach has limits in terms of size and position of the images compared to traditional HUDs that use the windshield as a screen. We're also starting to see similar lens-based aftermarket options that can be added to any car. Last year I tested a portable HUD called Navdy that taps into a car's OBD-II port to provide info on speed and RPM and uses built-in GPS and Google Maps to show the surrounding area, display speed limits and route you to your destination. Navdy also connects to an Android or iOS smartphone via Bluetooth to display data from phone calls, texts and music playing on a connected device, and it's simple to use and easily visible in almost any lighting condition. While Navdy is still available online, late last year the company ran into financial difficulties, and product support has been halted. I recently tested a new portable HUD called Hudly that's not quite fully baked and falls short of Navdy because it doesn't tap into an OBD-II port. Since a companion smartphone app for Hudly isn't scheduled to launch until next month, for now it only mirrors what's on a smartphone. So it can be used for nav and other apps, and its features are very limited. Between automakers adding HUDs in more reasonably priced cars and the aftermarket filling in the gaps for existing vehicle owners with add-ons, the technology is becoming more prevalent and affordable. And it's also getting better.

Mini Minor to be co-developed with Toyota

It was back in 2011 when Mini first showcased the prospect of an even smaller hatchback with the Rocketman concept at the Geneva Motor Show. In the nearly four years since, parent company BMW has hemmed and hawed on the possibility of putting it into production, but the latest word from Europe has it that the project is a go. According to Automobile magazine, Mini is realigning its product portfolio into five pillars: the essential hardtop we've already seen (available in two/three- and four/five-doors), the convertible, the upcoming new Clubman wagon (coming this summer with full-size auxiliary suicide doors on both sides), the next-gen Countryman crossover in 2016 and two new model lines. One will be the production version of the Superleggera roadster concept, earmarked for 2018. The other will be the Minor, a smaller city car reviving a long-gone model name and presaged by the aforementioned Rocketman concept. But for that last one, Mini won't go it alone. To develop the mini Mini, BMW will reportedly turn to its partnership with Toyota. The relationship is already set to yield a new Supra and Z4 and share fuel cell and other technologies. But this would broaden the partnership to include a small hatchback. However rather than use the existing (or next-gen) Aygo, which is already built under joint venture with PSA Peugeot Citroen (with which BMW previously had a joint engine venture), word has it that the BMW and Toyota will develop a new platform for the project – one that will be used by both partners. The new product plan doesn't leave much room for the Mini Coupe and Roadster (which have already been discontinued), for the Paceman three-door crossover (which will suffer the same fate) or for the projected seven-seater minivan. But the addition of the new Superleggera roadster and super-mini Mini aren't likely to leave us wanting for either. Related Video: