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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."

NHTSA opens safety investigations into Toyota, GM and Honda crossovers

The National Highway Traffic Safety Administration is evidently keeping itself very busy these days, as the federal agency has just announced it is launching or renewing investigations into Toyota, Honda and General Motors crossovers.
2006-2008 model year Toyota RAV4 crossovers are under review for allegations of rear tie-rod rust which can result in failure. NHTSA also said it is probing some 35 complaints about 2005 Honda Pilot models with inappropriate activation of the vehicles' stability control system. The alleged malfunction can cause the vehicles to slow down or stop in bad unsafe situations. At the moment, NHTSA is reviewing a petition regarding the Pilot issue, a move that will determine whether it needs to open a full-blown investigation.
In addition, Saturn Outlook and GMC Acadia three-row crossovers built in 2007-2009 are getting looked at for "loss of low beam headlamp" function. One complainant said the wiring in his Outlook overheated and melted. NHTSA says it has received 415 complaints about the problem and a GM spokesman confirmed that the automaker already started a "Customer Satisfaction Program" in December to address the issue.

Toyota and Lexus recall models for inadvertent airbag deployment

The Basics: Toyota will recall 320,000 examples in the US of the 2003-2006 Land Cruiser, 2004-2006 4Runner, 2005-2006 Tundra and Sequoia, 2003-2006 Lexus LX470, and 2004-2006 GX470. The Problem: The curtain shield airbags that come down from the roof can inadvertently deploy shortly after vehicle startup. This is due to improper programming of the airbag control module. Injuries/Deaths: "Toyota is not aware of any crashes caused by the condition. We have received reports alleging injuries such as abrasions and ringing in ears," company spokesperson Cindy Knight told Autoblog. The Fix: Toyota and Lexus dealers will replace the airbag control module with a new part, which will have improved programming. If You Own One: Toyota and Lexus will notify affected owners by mail early this month. Related Video: Toyota and Lexus Recall Certain Land Cruiser, 4Runner, Tundra, Sequoia, LX, and GX Vehicles February 02, 2016 TORRANCE, Calif., February 2, 2016 – Toyota Motor Sales, U.S.A., Inc. today announced that it is conducting a safety recall of approximately 320,000 Model Year 2003-2006 Land Cruiser; 2004-2006 4Runner; 2005-2006 Tundra and Sequoia; 2003-2006 LX 470; and 2004-2006 GX 470 vehicles. The involved vehicles are equipped with side Curtain-Shield-Airbags (CSAs) which deploy from the roof in the event of certain types of crashes. Due to improper programming in the airbag control modules, there is a possibility that, under certain specific and limited conditions shortly after startup, the CSAs and seat belt pretensioners could activate when not necessary. Unexpected activation of the CSAs could increase the risk of injury to the occupant. All known owners of the involved vehicles will be notified by first class mail. Toyota and Lexus dealers will replace the airbag control module with one which has an improved programming at no cost to owners. Information about automotive recalls, including but not limited to the list of involved vehicles, is subject to change over time. For the most up-to-date Safety Recall information on Lexus, Toyota and Scion customers should check their vehicle's status by visiting http://www.toyota.com/recall and entering the Vehicle Identification Number (VIN). Safety Recall inquiry by individual VIN is also available at the NHTSA site: safercar.gov/vin. For any additional questions, customer support is also available by calling Toyota Customer Service at 1-800-331-4331 or Lexus Customer Service at 1-800-255-3987.