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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."

Toyota recalls 690,000 Tacoma trucks for rusty leaf springs, fire risk

Toyota has announced that it will be issuing a recall of 690,000 Tacoma pickups from model years 2005 through 2011. The affected vehicles include both the four-wheel-drive model and the two-wheel-drive PreRunner (but not the standard 4x2 pickups), which may have a rather serious problem with their rear suspensions.
In some cases, corrosion and stress could cause one of the three or four leaves in the rear suspension's leaf springs to fracture. While the trucks can still be driven with a broken leaf, Toyota is concerned that it could move out of position and impact other components in the rear of the truck, with a particular focus on the fuel tank. Needless to say, but a piece of metal continuously impacting anything, let alone the fuel tank, is cause for concern.
As of this writing, there have been no reports of crashes, injuries, fires or deaths due to this problem, although that won't stop Toyota from informing all affected customers of the issue. Those 690,000 owners will need to report in to dealers for inspections and, if necessary, repairs.

Honda Civic losing ground to Toyota Corolla, sales crown threatened

Oh, what a difference a year has made. When the numbers were tallied for 2013, the Honda Civic was riding high by claiming its segment's sales crown in the US despite being challenged by the latest generation of the Toyota Corolla for part of the year. However, with just a month to go in the battle for C-segment supremacy in 2014, it looks like Toyota gets to hoist the trophy this time. Looking at November sales numbers, Honda moved 300,644 Civics through the first 11 months of the year, down 2.1 percent in volume. Furthermore, for the month alone, the company sold 23,060 Civics, a 12.3 percent drop. Meanwhile, on Toyota's side, business has been booming comparatively. Through the first 11 months it sold 309,373 Corollas, a 10.6 percent jump, and for November alone it moved 25,609 examples, a 14.2 percent improvement. With fewer than 10,000 cars between them, it would take quite a December slump for the Corolla to lose this fight. According to The Truth About Cars, the Civic actually started out the 2014 somewhat positively with 5 percent growth over the previous year, though still behind the Corolla's figures. However, the Honda has seen a slide since then with five consecutive months of sales drops. Meanwhile, the Toyota has generally kept showing growth. Being the newer model of the two, the Corolla comes to this fight with an advantage. Honda hasn't let the Civic languish; it gave the model a CVT in 2014 to boost fuel economy. That's nothing like the Toyota's thorough recent rethink, though. According to TTAC, Honda does have reason to crow about the Civic, just not necessarily in the US. The model is on track to be the bestselling vehicle in Canada for the 17th consecutive year and have its best sales since 2008 there.