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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."

Autoblog Minute: UAW and FCA avoid strike, Clarkson teases new show

FCA avoids a worker strike, a former Top Gear host teases us with a picture from Amazon's new car show, and Toyota predicts autonomous cars by 2020. Autoblog senior editor Greg Migliore reports on this edition of Autoblog Minute Weekly Recap. Show full video transcript text [00:00:00] FCA avoids a worker strike, a former Top Gear host teases us with a picture from Amazon's new car show, and Toyota predicts autonomous cars by 2020. I'm senior editor Greg Migliore and this is your Autoblog Minute Weekly Recap. A UAW strike of FCA was avoided thanks to a zero-hour tentative agreement reached this week. Worker concerns that were renegotiated in the new [00:00:30] deal include adjustments to the two-tier wage scale, health care costs, and production outsourcing. Now check-in with Autoblog as we update our reports on this evolving story. Shooting began on Amazon Prime's new automotive show starring the former Top Gear crew. That's Jeremy Clarkson, Richard Hammond, and James May. Now Clarkson threw out a tweet from day one of filming on location at Algarve Motor Park in Portugal. The picture features the show's [00:01:00] three stars and crew posing with the holy trinity of hyper cars. That's a McLaren P1, a Ferrari LaFerrari, and a Porsche 918 Spyder. This Prime show is being called Gear Knobs though the name is unofficial. Now if a tweet is any indication of what we can expect, who cares what it's called this is gonna be awesome. (Eds Note: Clarkson tweeted Friday that the show will not be called Gear Knobs.) Toyota predicts drivers could be obsolete on highways as early as 2020, with technology dubbed the Toyota Highway Teammate or THT. Toyota is using a modified [00:01:30] Lexus GS to show what this is capable of. THT is already able to create a driverless freeway car that's capable of changing lanes, making passes and taking curves. Plus, it can keep safe distances from other vehicles. Toyota is currently testing this on Tokyo's Shuto Expressway. Those are the highlights from the week that was. Be sure to check out my full recap this Saturday. And I'll have some added insight on the BMW M4 GTS. For Autoblog, I'm Greg Migliore. [00:02:00] Show Logo Autoblog Minute is a short-form video news series reporting on all things automotive. Each segment offers a quick and clear picture of what's happening in the automotive industry from the perspective of Autoblog's expert editorial staff, auto executives, and industry professionals.

Toyota, Honda, Mazda and Nissan recall 3.4 million vehicles for faulty airbags

Most vehicle recalls that take place these days are a result of some problem that happens during the manufacturing process by the automaker, but as we see here, parts suppliers can also factor in to problematic safety issues. Automotive News is reporting that a total of 3.4 million vehicles produced by Japanese automakers between 2000 and 2004 are being recalled globally due to faulty airbags produced by an outside supplier, Takata Corp.
According to the report, vehicles from Toyota, Honda, Nissan and Mazda are being recalled because of passenger front airbags that do not inflate properly. Globally, Toyota is said to be recalling around 1.73 million cars including 510,000 in the US composed of Toyota Corolla, Matrix, Sequoia and Tundra as well as the Lexus SC430 for the 2001 through 2003 model years; this is the second time this year the 2003 Corolla and Matrix have been recalled for an airbag problem. Honda is recalling 1.14 million models, Nissan another 480,000 and Mazda 45,463. The article says that Takata supplied faulty airbags to non-Japanese automakers, but it did not specify which ones.
Honda and Toyota have released information on their own websites about the recall, while Nissan and Mazda have not yet commented. Read official press releases from Honda and Toyota, below, and look for updates as we have word from the others.