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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."

Total auto recalls already on record pace in 2014

If you've noticed that there have been more recalls than usual this year, you may be on to something. According to a report from the National Highway Traffic Safety Administration, the US market is on pace to break a record for recalls. In 2013, 22 million cars were recalled. We're only a third of the way through 2014, though, and we've already halved that figure, with 11 million units recalled. That's wild.
Considering the past few months, it shouldn't be a surprise that General Motors is leading the charge, with six million of the 11 million units recalled coming from one of the General's four brands. Between truck recalls, CUV recalls and the ignition switch recall, 2014 hasn't been a great year for GM.
Other recall leaders include Nissan (one million Sentra and Altima sedans), Honda (900,000 Odyssey minivans), Toyota (over one million units in a few recalls), Volkswagen (150,000 Passat sedans), Chrysler (644,000 Dodge Durango and Jeep Grand Cherokee SUVs) and most recently, Ford (434,000 units, the bulk of which were early Ford Escape CUVs). So while it's been a bad year for GM so far, its competitors aren't doing too well, either.

Toyota Pro/Celebrity race switching from Scion tC to FR-S [w/video]

Toyota has announced that the rear-wheel-drive Scion FR-S will replace the front-wheel-drive Scion tC as the racecar used by actors, singers and celebrities of all grades in its annual Toyota Pro/Celebrity Race. It's the first time a rear-drive vehicle has been used for the event in 27 years, with the tC having been in use since 2005, and the FWD Celica before that. This year's race takes place on April 20th amidst the festivities of the Toyota Grand Prix of Long Beach weekend.
The racing FR-S, which debuted today at the Chicago Auto Show, won't be left stock either, but rather outfitted with a range of official Toyota Racing Development parts and equipment, such as a stainless steel exhaust, new coil overs and springs, upgraded brakes, a bigger air intake and 18-inch wheels, not to mention all of the safety equipment required to keep the celebrities and pro drivers safe. The company says the performance mods have lifted horsepower to 210 from the standard car's 200. Check out the build process for the cars in the video below to see just how much work's been done.
The Toyota Pro/Celebrity race is also about more than just letting celebrities and pros do battle on a road course. The spectacle helps raise money for "Racing for Kids," a non-profit charity that supports children's hospitals in the US.