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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."

Brand new cars are being sold with defective Takata airbags

If you just bought a 2016 Audi TT, 2017 Audi R8, 2016–17 Mitsubishi i-MiEV, or 2016 Volkswagen CC, we have some unsettling news for you. A report provided to a US Senate committee that oversees the US National Highway Traffic Safety Administration (NHTSA) and reported on by Automotive News claims these vehicles were sold with defective Takata airbags. And it gets worse. Toyota and FCA are called out in the report for continuing to build vehicles that will need to be recalled down the line for the same issue. That's not all. The report also states that of the airbags that have been replaced already in the Takata recall campaign, 2.1 million will need to eventually be replaced again. They don't have the drying agent that prevents the degradation of the ammonium nitrate, which can lead to explosions that can destroy the airbag housing and propel metal fragments at occupants. So these airbags are out there already. We're not done yet. There's also a stockpile of about 580,000 airbags waiting to be installed in cars coming in to have their defective airbags replaced. These 580k airbags also don't have the drying agent. They'll need to be replaced down the road, too. A new vehicle with a defective Takata airbag should be safe to drive, but that margin of safety decreases with time. If all this has you spinning around in a frustrated, agitated mess, there's a silver lining that is better than it sounds. So take a breath, run your fingers through your hair, and read on. Our best evidence right now demonstrates that defective Takata airbags – those without the drying agent that prevents humidity from degrading the ammonium nitrate propellant – aren't dangerous yet. It takes a long period of time combined with high humidity for them to reach the point where they can rupture their housing and cause serious injury. It's a matter of years, not days. So a new vehicle with a defective Takata airbag should be safe to drive, but that margin of safety decreases with time – and six years seems to be about as early as the degradation happens in the worst possible scenario. All this is small comfort for the millions of people who just realized their brand-new car has a time bomb installed in the wheel or dashboard, or the owners who waited patiently to have their airbags replaced only to discover that the new airbag is probably defective in the same way (although newer and safer!) as the old one.

Recharge Wrap-up: 10-year sentence for biodiesel fraudsters, overhead fast charging EV buses in Luxembourg

Toyota will use addressable TV advertising to target potential Prius Prime customers. By choosing to advertise in households with specific attributes, Toyota hopes to grab the attention of buyers who "see their vehicle as an extension of their consumption of advanced technology," according to Toyota Motors Sales media manager Lisa McQueen. The ad depicts a person who is skeptical of various inventions throughout history until he finds himself inside the Prius Prime. Hyundai has also used addressable TV ads for its Genesis brand. Read more at Automotive News. Two Florida men have each been sentenced to over 10 years in prison for biodiesel credit fraud. Thomas Davanzo and Robert Fedyna of Gen-X Energy Group and its subsidiary Southern Resources and Commodities were convicted of buying fuel that had already been sold with Renewable Identification Numbers, then fraudulently claiming more credits on that fuel. The scheme raked in more than $46 million, mostly in selling the fraudulent credits. Critics of the Renewable Fuel Standard point to incidents like this as a reason to oppose the program. Read more from Reuters. Volvo electric buses in Luxembourg will use Heliox Fast Charge systems. Public transport operator Sales-Lentz has ordered three of the Heliox systems that will charge the buses using pantograph (overhead wire) contacts. The chargers will be placed at end-of-route stops for opportunistic charging of the transport agency's four Volvo 7900 electric buses. The 450-kW, Wi-Fi-enabled OppCharge system automatically connects the charger to contact plates on the roofs of the vehicles, charging them in three to six minutes. Read more at Green Car Congress. Related Gallery 2017 Toyota Prius Prime Advanced View 35 Photos News Source: Automotive News, Reuters, Green Car CongressImage Credit: Volvo Buses Government/Legal Green Marketing/Advertising Toyota Volvo Biodiesel Technology Electric recharge wrapup