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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."

Will Toyota lose up to 70% of its workforce in TX relocation?

Toyota's decision to move its US headquarters from its longtime home in Torrance, CA, to Plano, TX, was one of the biggest stories in the automotive industry this spring. With several months since the announcement, more details about the plan have leaked out. It seems that pulling up stakes could mean an even larger shakeup in the Toyota workforce than first thought.
According to Automotive News, Toyota intends to hang onto around 50 percent of its workforce in the move to the Lone Star State. However, even that figure might be optimistic. According to an unnamed insider speaking to AN, there is a fear the actual number could be closer to 30 percent. For comparison, Nissan retained about 42 percent of its workers in its move from California to Tennessee.
The actual percentage making the move is a mystery because Toyota is still rewriting its job descriptions under a single set of guidelines. The changes affect benefits, bonuses and the reporting structure, according to Automotive News, and employees' reactions could play a big role in who decides to go. According to an unnamed worker speaking to AN, the wait is hurting morale. Some people are even applying at the nearby Honda headquarters.

Toyota confirms all-wheel drive V8 hybrid for TS040 LMP1 car in 2014

The 2014 FIA World Endurance Championship is gearing up to be one of the most exciting seasons of endurance racing in recent memory. All of the factory-entered LMP1 class cars are using hybrid powertrains, and Porsche is returning to the top class of the sport after a 16-year absence. Don't count out Toyota, though. The team has just revealed the first official details about its 2014 TS040 LMP1 car, and it has a big surprise - all-wheel drive.
The TS040 will follow Audi's lead and will use a combination motor and generator to power the front wheels. The system will generate power under braking and will use it up when accelerating to give a boost in traction over last year's rear-wheel-drive Toyota TS030. Toyota will stick with a gasoline-fueled, naturally aspirated 3.4-liter V8 to feed the rear wheels and will take on Audi's diesel, turbocharged 3.7-liter V6 and Porsche's gasoline-fueled, turbo 2.0-liter four-cylinder.
Sadly, there are no real pictures of the TS040 yet. Toyota is holding off on unveiling the car until the end of March at the WEC test at the Paul Ricard circuit, and the racing season doesn't begin until April 20 with the 6 Hours of Silverstone. You can read the whole press release about the TS040 below.