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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."

Recharge Wrap-up: Japan supports hydrogen, Fools against fuel cells, BlueIndy controversy

Japan hopes to expand the use of hydrogen energy by subsidizing fuel cell vehicles, according to The Japan News. The trade ministry plans to include the subsidies in its 2015 budget to coincide with the expected launch of Toyota's Fuel Cell Vehicle and the Honda FCEV hydrogen car. By jump-starting purchases of hydrogen cars, Japan hopes that innovation and mass-production will get a boost and the cost of fuel cell vehicles will be competitive with gasoline-powered models by the year 2025. Japan plans to have 100 hydrogen fueling locations operating by March 2016, and wants to halve the cost of building those stations by 2020. The amount of the subsidies has not yet been set. Investing website The Motley Fool isn't quite as optimistic as Japan about hydrogen cars, and is instead bullish about Tesla Motors. The Fool points to Tesla's strong stock performance, and predicts future growth will come from more car models in the future - starting with the Model X - as well as the company's proposed Gigafactory for manufacturing batteries. If Tesla's charging technology continues to catch on, that only improves its financial prospects. The article has some harsh words, however, for hydrogen: "Fuel cells are an inferior automotive technology and for fundamental efficiency, cost, and infrastructure reasons always will be mere compliance gimmicks." Yeesh. As part of a program to build charging stations for the Indianapolis EV carsharing service BlueIndy, utility company Indianapolis Power & Light (IPL) wants to raise its electricity rates an average of 44 cents a month per residential customer to help pay for its share of the project. State consumer advocacy agency Indiana Office of Utility Consumer Counselor and consumer watchdog group Citizens Action Coalition oppose the plan, according to Greenfield, Indiana's Daily Reporter. The BlueIndy program, which is a partnership between the city of Indianapolis and battery manufacturer Bollore Group, will provide up to 500 cars for rent at 25 charging sites around the city. Those who oppose the rate hike call IPL a monopoly and say the amount of the increase is not allowed under state law and that the program wouldn't benefit working class and low-income citizens. A hearing regarding IPL's proposal is scheduled for July 23. A Mitsubishi Outlander PHEV will run the 2014 Asia Cross Country Rally, Hybrid Cars reports. The rally covers 1,367 miles of woods, swamps and mountains from Thailand to Cambodia.

Audi outlasts rivals to win 13th Le Mans title

As is so often the case, the 2014 Le Mans was a war of attrition, and Audi managed to prevail once again after all 24 hours had been recorded in the history books, with its Audi R18 E-Tron Quattro claiming first and second places, followed by Toyota in third. Drivers Marcel Fassler, Andre Lotterer and Benoit Treluyer inherited the lead in their No. 2 Audi after the No. 7 Toyota, driven by pole-sitter Kazuki Nakajima, was forced to retire with electrical problems in the 15th hour.
The No. 2 Audi led the race until it was forced to the pits to replace a turbocharger in the 17th hour, allowing the No. 1 Audi, driven by Lucas di Grassi, Marc Gene (who was a last-minute replacement for Loic Duval, who crashed hard during practice) and defending champion Tom Kristensen, led the race until the 21st hour, when it too had to pit with turbocharger issues. This gave the No. 20 Porsche of Timo Bernhard, Brendon Hartley, and Mark Webber the lead until it was forced off the track with gearbox problems, eventually finishing in 38th position.
In LMP2, the Jota Sport Zytek Z11SN-Nissan driven by Simon Dolan, Harry Tincknell and Oliver Turvey claimed victory, the first five LMP2 finishers all powered by Nissan. Down a level in GTE-Pro, No. 51 AF Corse Ferrari 458 Italia GT2 driven by Gianmaria Bruni, Toni Vilander and Giancarlo Fisichella finished one lap ahead of the leading Corvette Racing C7.R. And finally, the No. 95 Aston Martin Racing Vantage GTE driven by Kristian Poulsen, David HeinemeierHansson and Nicki Thiim won the GTE-Am race two laps ahead of a Proton Porsche 911 GT3 RSR.