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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."

Hurricane Sandy cost automakers 15,000 vehicles, may have ruined up to 200k

Hurricane Sandy was the largest Atlantic storm in US history, and its total economic impact is just now coming into view. According to Automotive News, Toyota, Chrysler, Nissan and Honda are set to scrap around 15,000 new vehicles ruined by the storm. Nissan alone accounts for about 40 percent of those, with 6,000 Nissan and Infiniti models deeded "un-saleable" due to damage. The company saw 56 dealerships shuttered due to the storm, but 51 of those have since reopened.
Toyota, meanwhile, had some 4,000 vehicles at its Newark port facility, and of those, 3,000 may be scrapped. An additional 825 were dealer inventory when they were ruined. Honda and Acura dealers are reportedly sending 3,440 vehicles to the salvage yard. By comparison, Chrysler weathered the storm fairly well with 825 units destroyed, while Hyundai suffered only 400 lost units and Kia scrapped around 200.
As you may recall, Fisker also suffered some losses, and Automotive News reports the manufacturer saw 320 Karma models damaged beyond repair. Ford and General Motors have yet to come up with estimates, and no automaker has commented on the full cost of replacing the vehicles.

Ford F-150, Chevy Silverado, Toyota Tundra flunk IIHS headlight test

The Insurance Institute for Highway Safety put pickup truck headlights to the test and found that the majority of them were equipped with subpar units. The 2017 Honda Ridgeline was the only truck to earn a rating of "good." The large pickup truck test was comprised of the: 2016 to 2017 GMC Sierra, 2017 Nissan Titan, 2016 Ram 1500, 2016 to 2017 Chevrolet Silverado, 2016 to 2017 Ford F-150, and 2016 to 2017 Toyota Tundra. The Sierra's headlights earned a rating of "acceptable," the headlights found on the Titan and Ram 1500 were found to be "marginal," and the ones on the Silverado, F-150, and Tundra were rated as "poor." IIHS claims the F-150 was the most disappointing out of the large pickup trucks as both its halogen and optional LED headlights failed to provide adequate visibility during testing. The Ridgeline (which earned a "good rating"), is usually considered a midsize or small truck, though IIHS included it in the field of large pickups. The headlights on the 2016 Chevrolet Colorado, 2016 GMC Canyon, 2016 Nissan Frontier, and 2016 to 2017 Toyota Tacoma, which made up the small pickup truck group, all earned a rating of "poor." The IIHS claimed the Colorado had the worst headlights of any truck that was tested, as the base vehicle's units were only able to illuminate up to 123 feet in front of the car. The Ridgeline's headlights, for reference, were able to illuminate up to 358 feet in front of the vehicle. To conduct its test, the IIHS utilizes a special tool to measure how far light is projected out of the headlights in different driving situations. The trucks' headlights were tested in a straight line and in corners, while vehicles with high-beam assist were given extra praise. The headlights on the pickup trucks also mimic the testing that was done on small SUVs and cars earlier this year. Next year, automakers will need to fit their vehicles with headlights that earn a rating of either good or acceptable to earn the IIHS Top Safety Pick+. Related Video: