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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."

177k Toyota Camry Hybrids being recalled for brake issue

It looks like Consumer Reports might be getting part of what it wants regarding the Toyota Camry Hybrid and its braking system. Toyota is issuing what it calls a limited service campaign, rather than a full recall, covering about 177,500 of the hybrid sedans from the 2007 through 2011 model years because of an issue with the cars' brake fluid reservoirs.
The models have a filter separating two chambers of the brake fluid reservoir, and the part can get clogged over time. If this happens, the fluid level in one of the chambers can get too low and eventually cause the power assist to fail. There are multiple warning lights on the dashboard that illuminate over time if the filter gets obstructed, though. The company is replacing the entire reservoir with an improved unit, and the fix takes about two hours to perform.
Consumer Reports recently began asking for a recall on these models for the potentially clogged filters. The magazine also reported a second issue with the ABS brake actuator that could lead to a difficult to depress brake, but Toyota has increased the warranty on the part to 10 years or 150,000 miles.

Toyota launches new Passo hatchback in Japan [w/video]

With considerable manufacturing capacity here in the United States and even a NASCAR program, it'd be all too easy to categorize Toyota as an American automaker. Only it's not. It's Japanese, of course. And back in the Japanese Domestic Market, it offers a whole range of models we'll never see in North America. Models like the Crown sedan, Noah minivan and this, the new Passo hatchback.
Sold in various markets as the Daihatsu Boon, Daihatsu Sirion, Perodua Myvi and (for a time) the Subaru Justy, the Toyota Passo is a compact hatchback that slots in size-wise between the Yaris sold in America and the Aygo offered in Europe (except the Passo is taller than either).
Power comes from a 1.0-liter engine with 69 horsepower that can be had in front- or all-wheel drive, or a 1.3 driving 95 horses to the front wheels alone. A continuously variable transmission is on duty regardless of engine choice. Front-drive models get a stop/start system, but even all-wheel-drive versions are eligible for government tax credits. That's because, though the new Passo only appears to be mildly updated, the engines have been thoroughly reworked to deliver 30-percent better fuel economy than the previous model, coming in 20-percent better than the standards being enacted by the Japanese government for next year.