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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."

Recharge Wrap-up: Toyota Prius, V earn IIHS awards, Mitsubishi Outlander PHEV approved for V2H

The Toyota Prius and Prius V have earned IIHS 2015 Top Safety Pick+ ratings. The Prius V was singled out for its improved performance in the small overlap crash test. Lexus CT models built after September 2014 were also given the distinguished safety rating. In all, eight vehicles from Toyota and Lexus earned Top Safety Pick+ awards, while four more from Toyota and Scion were named Top Safety Picks. Read more in the press release below. The Mitsubishi Outlander PHEV can now provide power to the home in Japan. The vehicle-to-home capability requires the CHAdeMO quick charging socket and either Mitsubishi's own Smart V2H system, or the EVPower Station or Tsubaki eLINK system. The Outlander PHEV gained vehicle-to-home approval alongside all-electric vehicles because its electric motor doesn't run when used in for this purpose. The system allows owners to power their homes during outages and emergencies, and the Outlander PHEV can also directly power appliances with its 1500W AC100V power feeder. Read more at Green Car Congress. The Electric Vehicle Institute has published an updated "Plug-In Around the EV World" poster. The poster depicts the various connector types used by EVs. It shows the standard AC connectors for the US and Europe, DC and combination connectors for fast charging and, of course, Tesla's own charging connector for the Model S. It also shows the standard plug types used around the world, which are color coded by country on a world map. See the Electric Vehicle Institute's poster here, or read more at Green Car Reports. Toyota Decks the Halls with IIHS 2015 'Top Safety Pick' Awards Eight Toyota and Lexus Models Earn Institute's Highest Top Safety Pick+ Four Toyota and Scion Vehicles Named Top Safety Picks December 23, 2014 TORRANCE, Calif., Dec. 23, 2014 - On the 12th day of Christmas, the Insurance Institute for Highway Safety (IIHS) gave to Toyota, 12 awards awarding. In fact, the automaker won more awards than any other automaker, including the most of the Institute's highest honor. In all, eight Toyota and Lexus vehicles earned a Top Safety Pick+ rating. IIHS in particular recognized the Prius V for its significantly improved performance all-around in the small overlap crash test – naming it a Top Safety Pick+. The Toyota Sienna was also the only minivan awarded the 2015 Top Safety Pick + designation. IIHS also recognized four additional Toyota and Scion vehicles as 2015 Top Safety Picks.

Toyota asking NHTSA for fuel cell car safety exemption regarding electric shocks

Toyota is requesting an exemption from federal safety regulations that govern electric cars as it prepares to launch a small-scale hydrogen fuel-cell vehicle fleet.
The Japanese automaker is targeting Federal Motor Vehicle Safety Standard 305, which covers the packaging of high-voltage parts in electric cars. According to Uncle Sam, these systems need to be isolated so that passengers and first responders aren't electrocuted in the event of a crash. That seems pretty smart, but it's become a problem for Toyota's upcoming production fuel cell vehicle, as the mechanism that prevents electric shocks in low-speed crashes will apparently simply keep Toyota's car from even functioning.
Instead of the federally approved system, Bloomberg reports that Toyota plans to insulate the high-voltage wires and cables in the car, along with shielding electrical components like the fuel cells, electric motor and batteries with (presumably non-conductive) metal barriers.