2002 Toyota Navigation on 2040-cars

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Toyota temporarily idles pair of Indian plants due to labor unrest

The Detroit News reported today that Toyota will restart production at two Indian plants, following a shutdown on Monday.
Factory labor, management and police in Asia engage in the kind of violent altercations that we're not used to, having almost entirely walked away from the overtly brutal relations epitomized by the Pinkerton Detective Agency and the Flint Sit-Down Strike. In India, a plant owned by a Ford transmission supplier plant was shut down in 2009 after incidents between workers and armed men around the same time as Ssangyong workers occupied a factory in South Korea, in 2012 Suzuki Maruti workers rioted over wages around the same time upset employees beat a ceramics factory president to death in retaliation for a labor leader's killing.
Toyota is the latest to company trying to avoid that road. The Detroit Free Press reported earlier this week that it shut down two plants in India after 11 months of acrimonious wage negotiations and arbitration have gone nowhere. Toyota said the plant workers in Bidadi, near Bangalore, had deliberately stopped production at times over the past 45 days and threatened management. The workers said they wanted their wages raised by an amount already agreed to by management, but that management had reneged; news reports weren't clear on the amount, some saying nearly 10,000 rupees ($165 US) more per month, another saying 4,000 rupees ($65 US), but reports agree that Toyota has said it will only go as high as 3,050 rupees ($50 US).

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 has now sold over 7 million hybrids

You take your victories where you can. In Toyota's case, that means disclosing the cumulative total of hybrid sales since the first Prius was sold in Japan in 1997. And that number is impressive. During its monthly conference call discussing sales, Toyota representatives noted that the automaker has sold over 7 million hybrids during the past 17 years. The Japanese automaker started selling the Prius in the Japan in 1997 (and in US in 2000) and firmly established itself as the world's largest hybrid maker. Today, Toyota sells four Prius models as well as gas-electric versions of the Camry, Avalon and Highlander in the US. Of course, such big sales aren't always easy to match, and Toyota's been lagging behind 2013's numbers all year. Including its Lexus division, Toyota's green-car sales including the low-volume RAV4 electric vehicle fell 10 percent from a year earlier in September to just over 21,000 vehicles. Through the first three quarters of the year, Toyota's green-car sales were down 9.1 percent to almost 247,000 vehicles. That still dwarfs any other automakers' green-car numbers. Toyota crossed the 6 million hybrid threshold in January when it doubled the 3 million total from March 2011. Toyota will start selling its first mass-produced hydrogen fuel-cell electric vehicle in Europe next summer, and hopes that it will repeat the long-term success that the Prius has enjoyed, according to Automotive News Europe. For a transcript of the September sales call, click here.