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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 recalling select 2014 Camry and Avalon models

Toyota has announced a rather small voluntary recall, affecting 5,650 Avalon and Camry sedans from model year 2014. Both gas and hybrid models are included in the action.
This recall focuses on the left front lower suspension arm, which may have a bad bolt connecting it to the ball joint. If the car hits a big enough pothole - a real concern as we head into winter - or suffers a major impact, the two components could separate, at which point steering control would more or less vanish.
According to Toyota, there have been no crashes, injuries or deaths due to this problem. Toyota is notifying owners, who will need to report to dealers for a free replacement lower suspension arm.

How platform problems are delaying next-gen Prius

Short-term pain for longer-term gain? That may be the prognosis for the next-generation Toyota Prius, the world's best-selling hybrid. But, hey, the new version might get holiday season debut, now. Toyota is upgrading some of its most popular models and trying to cut long-term costs with components that can be used on multiple models on the new Toyota New Global Architecture platform, Automotive News says. That means more parts that can be used for the Camry, Avalon (not big stretch, since the Avalon is basically a rich man's Camry) and Corolla in addition to the Prius. The downside, of course, is that this takes a bit more engineering and certainly more time. In the case of the Prius, that means pushing back the start of production from next summer to December 2015. But Automotive News also says the Prius may have an all-wheel-drive option. Happy Holidays. The report is in update from Automotive News Europe, which cited folks familiar with the process who were not identified and said late last month that the production of the fourth-gen Prius would be pushed back by about six months as engineers continue to tweak the hybrid powertrain for maximum efficiency. The goal is around a 10 percent improvement in fuel-efficiency thanks to an upgraded powertrain and lower vehicle weight. Toyota spokeswoman Amanda Rice told AutoblogGreen in an email that the company doesn't comment on future products, so we'll just have to keep an eye out.