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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."

Toyota celebrates 30 years of 4Runner with... incentives?

Many Americans view their 30th birthdays as significant milestones, even though the average life expectancy here is more than 2.5 times that age. So you might think Toyota would be keen to party over the 30th anniversary of its 4Runner, since most models don't even live to half that age. You can put that idea away unless you consider discounts of $500 to $1,000 something worthy of cake and kazoos, since it appears that's all the birthday SUV will get. That's right, not even a trim-and-tape special edition or so much as a sticker. We asked Toyota for comment and were told they had "No other 30th anniversary 4Runner items to announce at the time."
So, about those incentives: they climb from $500 on the SR5 and Trail editions to $750 on Premium models and $1,000 on the Limited trims. Toyota says they're available at dealerships now and will last for the entire year. There's a press release below with a little more background, and there's a sad violin playing somewhere in the distance.
Disappointed, party of one, your table is now ready...

Toyota says you might have the 40-millionth Corolla ever built

The guy who bought the 50-millionth Toyota in the US got a free Camry and RAV4, but whoever in the world bought the 40-millionth Corolla in August gets a hearty "thank you" from the Japanese automaker. On sale since 1966, the Corolla is the best-selling nameplate in the world by a goodly margin (more than the Volkswagen Beetle and Ford Model T combined). So while you'd think that vehicle number 40 million would be sitting in a museum somewhere, Toyota can't even say in which country this milestone Corolla was sold, let alone to which customer.
One reason that Toyota is unsure where this Corolla was sold is the fact that the Corolla name itself is more than just the compact sedan sold in the US. On our shores alone, sales of the Matrix are lumped in with the Corolla, but around the world, numerous vehicles wear the Corolla name or share its platform. Scroll down for Toyota's press release, and it has also put together a website celebrating 47 years and 40 million sales for the Corolla... and counting.