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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."

How Toyota's Le Mans racer may make its next Prius even better

The supercapacitor technology in the Toyota TS040 "offers great possibility for production car use." – Amanda Rice, Toyota Pop-culture junkies familiar with 1980s touchstone movies will hear the word "capacitor" and think Back to the Future. But the concept of supercapacitors being used in upcoming production models is being pushed by Toyota, not DeLorean. And because of that push, the future might look a little brighter for the Prius. The Japanese automaker will likely apply electric-motor technology used in Toyota's 24 Hours of Le Mans entry – the TS040 – in future versions of the world's best-selling hybrid, Australian publication Drive.com.au says, citing an interview with Toyota Motor Sports' Yoshiaki Kinoshita. Specifically, the racecar uses supercapacitors because they're effective at storing energy created when the vehicle is under braking, only to quickly redistribute it on demand for rapid acceleration. Kinoshita said Toyota may apply this technology to the Prius within the next five years. While declining to comment on specifics, Toyota spokeswoman Amanda Rice tells AutoblogGreen that the Le Mans vehicle "represents an advanced vehicle laboratory for hybrid vehicle and component development. The supercapacitor technology used in this vehicle with its fast charge and discharge capability offers great possibility for production car use." In her email, Rice added that the next-generation Prius will have smaller electric motors with greater power density and thermal efficiency, so let's add that to what we know or think we know about the fourth-generation model. Toyota entered two vehicles in this year's Le Mans race, and one of them had secured the pole-position and was leading much of the race before calling it quits 15 hours in because of electrical issues. Audi ended up winning the race, marking its 13th victory in the history of the French endurance contest.

Aston CEO claims Cygnet cancelled because Toyota is dropping iQ in 2014

While slow sales and a $50,000 price tag may have been contributing factors to the Aston Martin Cygnet being cancelled last month, Aston Martin CEO Ulrich Bez is pointing the finger at Toyota for the demise of this luxurious little city car. In a discussion with Autocar, Bez is quoted as saying that the ultimate reason the Cygnet was cut is because Toyota plans on dropping the iQ (on which the Cygnet is based) in 2014 - a claim denied by the Japanese automaker.
Interestingly, the article also cites another publication reporting that a Toyota importer in the Netherlands heard the same news as Bez, and it has already stopped importing the cars. If the European Toyota iQ is cancelled, that would likely spell the end of the slow-selling Scion iQ in the US, which has sold just 3,365 units through September (a drop of 51 percent year over year).
Regardless of why production of the Cygnet ended, Bez also says that a lack of support from Toyota on the project prevented it from being offered in the US or receiving a supercharged engine, which are two factors that likely would have made the car appealing to more buyers.