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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."

North American production of foreign marques to jump in 2014

Wards Auto has released its North American Light Vehicle Production Forecast for 2014, and the report predicts foreign manufacturers will increase production on the continent some 3.9 percent by 2014. If accurate, that should see 123,000 additional cars, trucks and vans produced in North America, swelling the total number of units produced both by domestic and foreign manufacturers to 16.9 million light vehicles from a projected 15.6 million in 2013. Much of the increase can be attributed to the fact that Toyota intends to produce another car at its Blue Springs, MS plant as well as a new Lexus model at its Georgetown, KY facility in a year's time.
Likewise, Volkswagen intends to move production of a currently imported model to its plant in Puebla, Mexico. Daimler, Honda, Nissan and Mazda also plan to build additional models on North American soil for the first time. Around two-thirds of the new North American manufacturing will take place in Mexico, helping the country soak up a full 20 percent of the content's automotive production for the first time. You can head over to the Wards Auto site for the full report.

Toyota U2 urban utility concept inspired by Maker Faire [w/video]

There's a quiet revolution happening in US cities. People want to mix an urban lifestyle with a connection to nature and appreciation for craftsmanship. The result of all of this is folks pursuing things as varied as urban farming, home brewing and the whole maker movement. Toyota thinks it has the perfect concept for these intrepid customers with its new Urban Utility concept that it is debuting during a panel discussion hosted by Make: magazine in San Francisco and debuting publicly on September 20 at the World Maker Faire in New York City.
The Urban Utility concept can best be described as a modern take on the old panel van. Designers from Toyota's Calty Design Research center in California interviewed Maker Faire participants to find out what its users want from a novel vehicle like this. "Toyota saw an opportunity for a new approach to an urban vehicle based on increasing re-urbanization of our cities and urban drivers' desire for flexibility, fun and maneuverability," said Kevin Hunter president of Calty.
On the outside, the Urban Utility doesn't really scream for attention. It's meant to meet users "desire for greater utility but a smaller vehicle footprint," according to the release, but the shape is still very much a van. The designers do try to lend it some panache with the LED headlights up front and checker board side panels. It's really more about utility than looks, though, because the roof can roll back for taller loads, the rear glass retracts into the tailgate, and the whole rear can fold down as a ramp to load stuff more easily into the cabin. Toyota isn't talking about a powertrain yet but claims that the underbody is also especially durable for a long life in the big city.