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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."

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These are 2014's best-selling cars and trucks

Now that 2014 is no more than a set of numbers on spreadsheets, at last, the grist mill gets its first real load to chew on. The number one selling vehicle in America last year was the Ford F-Series, a fact that should surprise you only if your family name is Van Winkle and your naps tend to last 38 years, which is how long the Ford pickup has ruled our buying landscape. Even though series sales were down 1.3 percent, it still racked up 753,851 units. That's 2,065.3 sales per day, every day, all year. The Chevrolet Silverado, up 10.3 percent for the year, was still a daylight second at 529,755 units. The cab-and-bed love continued into third place with the Ram 1500-3500 trucks, gaining 23.6-percent year-on-year to clock 439,789 units. The robust turnout at The Bighorn and Jeep helped Fiat-Chrysler increase its sales by 16 percent, past the two-million mark. Our number one car? The Toyota Camry, staying in first place with a 4.9-percent sales boost to 428,606 sales, trailed again by the Honda Accord at number five with 388,374 sales. Accord sales rose six percent, and if it's any consolation to Honda for coming in second - not that it needs one - it is the only manufacturer to have three vehicles in the top ten. The rest of the list: the Nissan Altima with 335,644 sales (+4.7%), the Honda CR-V with 355,019 (+10.2%), the Toyota Corolla/Matrix combo with 339,498 (+5.9%), the Honda Civic with 325,981 (-3.1%), and the Ford Fusion with 306,860 sales (+2.9%). Total sales for the year were up six percent to 16.5 million vehicles, a volume not seen since 2006, aided by a strong December that was up by 11 percent year-on-year. Ford was the top selling brand overall but sales didn't really budge from 2013, while Subaru rocketed up 21 percent to finish with 513,693 sales. At the precious end, BMW, Audi, Porsche and Land Rover all had record years, and Kelley Blue Book thinks we could be looking at 17 million sales for the next two or three years. Looks like it's time to start making hay again... Featured Gallery Best-selling vehicles of 2014 View 10 Photos News Source: Detroit News, Associated Press Auto News Chevrolet Ford Honda Nissan RAM Toyota Car Buying Truck Sedan sales