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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 Camry could lose No. 1 sedan spot next year [w/video]

Eleven months after Toyota claimed the 2012 sales crown a couple of months early thanks to the Camry, the headlines this year have been quite a bit different to last. Even though the Camry remains the best selling car so far in 2013 and its volume has increased year-on-year, it has lost market share due to the 20-percent sales explosion in the midsize segment. That means people are buying more of the competitor offerings like the Honda Accord, Nissan Altima and Ford Fusion - the Altima, in fact, outsold the Camry by 100 units in March.
In July it was reported that Toyota was upping Camry incentives and fleet sales to keep its lead and that dealer inventory was climbing as, again, competitors got better at fighting the champion. In August Ford doubled down on production of the Fusion, adding a line in Flat Rock, MI to keep up with demand.
Bloomberg has a report looking at the numbers behind the Camry's dominance, as well as what appears to be a recorded group interview with Toyota USA CEO Jim Lentz, and wonders aloud whether the Camry will be able to hold its top spot in 2014. Barring catastrophe it has this year locked up, being more than 30,000 sales ahead of the next-best seller as of the end of August, but it has done so with higher incentives and lower transaction prices than its competitors. According to Strategic Vision the Camry's consideration rate among consumers has also declined by a percentage point, while the consideration rate for the Accord and Fusion has increased by one point and two points, respectively.

NHTSA may investigate new Toyota unintended acceleration case

After paying a $1.2-billion settlement to the US government last year, Toyota largely put the unintended acceleration recall behind it. Although, there were still some civil lawsuits to handle. A new case where the owner of a 2009 Lexus ES350 is petitioning the National Highway Traffic Safety Administration to open another analysis could draw the issue back to the forefront. Investigators are still deciding whether to research these claims further, though. According to this petition, the owner's wife was driving the ES350 in February 2015. While pulling into a parking space, the sedan allegedly surged forward, and there was a low-speed accident. The claim asserts there are at least two other similar cases in NHTSA's database: one in a 2009 Camry in 2009 and another in a 2010 Corolla in 2014. Specifically, this person wants an "investigation into low-speed surging in different models of Toyota automobiles in which the car starts accelerating and the engine RPM increases even when the accelerator pedal is not depressed," according to the agency. NHTSA will do further research into this person's claim and will decide whether to conduct a full investigation into the alleged issue. This won't be the first reappraisal of unintended acceleration in Toyotas by the agency in recent months, though. Between September 2014 and May 2015, NHTSA evaluated a similar petition with allegations covering 2006-2010 Corollas, and the government body decided to deny that one because the problem couldn't be replicated. Related Video: INVESTIGATION Subject : Low-speed surging Date Investigation Opened: JUL 09, 2015 Date Investigation Closed: Open NHTSA Action Number: DP15005 Component(s): VEHICLE SPEED CONTROL All Products Associated with this Investigation close Vehicle Make Model Model Year(s) LEXUS ES350 2009 Details Manufacturer: Toyota Motor Corporation SUMMARY: In a letter dated June 19, 2015, a consumer petitioned the National Highway Traffic Safety Administration (NHTSA) for an "investigation into low-speed surging in different models of Toyota automobiles in which the car starts accelerating and the engine RPM increases even when the accelerator pedal is not depressed." The petition was prompted by a February 2015 crash involving a model year (MY) 2009 Lexus ES350, which allegedly surged as the petitioner's wife was pulling into a parking spot.