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Former NHTSA chief may lead automaker-backed Takata investigation

An automaker-led effort may see the former head of the National Highway Traffic Safety Administration take on the probe into the Takata airbag inflator disaster. A coalition of at least ten automakers is in talks with former NHTSA administrator David Kelly, with unnamed sources familiar with the discussions telling The Wall Street Journal he is "among those we are considering to coordinate" the investigation.The Detroit News, meanwhile, is reporting he could be hired "in the coming days." Takata, the Japanese seatbelt and airbag manufacturer, has been the center of a defect scandal since last year. Takata is under fire for air bag inflators that can explode, shooting out metal and plastic pieces. At least five deaths and dozens of injuries have been linked to the problem worldwide. Earlier this year, Honda Motor Co., the automaker with the biggest exposure to the defective Takata air bags, was fined $70 million in the U.S. for not reporting to regulators some 1,729 complaints that its vehicles caused deaths and injuries, and for not reporting warranty claims. It was the largest civil penalty levied against an automaker. Should he take the role, Kelly would be at the fore of an investigation being assembled by an alliance of ten automakers, which includes the Detroit Three and Honda. Toyota first suggested a joint investigation back in December, The Journal reports. Kelly's goals, meanwhile, will be many. The Detroit News reports that questions abound regarding not only the recalled airbag inflators and the conditions that cause them to fail, but the whether the replacement units will have similar problems in the future. The automaker committee is far from the only one analyzing the airbag issue. Takata has assembled its own panel, led by former Secretary of Transportation Samuel Skinner, while NHTSA's deputy administrator, David Friedman, has brought in an outside engineering firm to investigate the inflators, The Detroit News reports. Separately, on Friday Takata Corp., the Japanese seatbelt and air-bag maker at the center of a defect scandal, is expecting more red ink for the fiscal year through March. It is projecting a 31 billion yen ($264 million) loss, worse than the previous forecast for a 25 billion yen ($214 million) loss, despite higher sales expected for the fiscal year. Ten automakers have recalled about 12 million vehicles in the U.S. and about 19 million globally for problems with the air bags.

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."

Toyota sold a million hybrids in last nine months, 6M since 1997

Toyota's first hybrid model – the Prius – went on sale in 1997 in Japan. It took 14 years for the company to see a cumulative total of three million hybrids (a mark reached in March 2011). Today, Toyota announced that its global sales figures of all of its gas-electric models (and there are a lot of them now, including ones we've barely heard of here in the US, like the Crown Majesta or the Harrier Hybrid) have reached six million. Toyota calculates that all those hybrids have saved 41 million tons of CO2 emissions from entering the atmosphere. Toyota's ever-increasing hybrid sales pace means the company sold as many in the last three years as it did in the first fourteen. As you can see in our chart, the trendline shows that we'll hit the next-million mark in short order. In fact, Toyota says that it sold a million hybrids in the last nine months, the shortest time it has ever taken the automaker to sell that many hybrids. Part of the reason is that there are 24 hybrid Toyota and Lexus models available around the world, and Toyota says another 15 will be coming in the next two years. Anyone want to guess when Toyota will hit seven million? August? Worldwide Sales of Toyota Hybrids Top 6 Million Units Toyota City, Japan, January 15, 2014-Toyota Motor Corporation announces that cumulative global sales of its hybrid vehicles topped the 6 million unit mark as of December 31, 2013, reaching 6.072 million units1. The latest million-unit milestone was achieved in the fastest time yet for Toyota, taking just nine months. Helping mitigate the environmental effects of vehicles is a priority at Toyota. Based on its belief that environment-friendly vehicles can only truly have a positive impact if they are widely used, Toyota has endeavored to encourage the mass-market adoption of hybrid vehicles. As of this month, Toyota sells 24 hybrid passenger car models and one plug-in hybrid model in approximately 80 countries and regions around the world. Furthermore, within the next two years, Toyota will launch a total of 15 new hybrid vehicles worldwide, including the new "Harrier Hybrid" in Japan on January 15 and the new "Highlander Hybrid" in the United States in the near future. Toyota will continue augmenting its product lineup even further and increasing the number of countries and regions where it sells hybrid vehicles.