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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 adds 1.6m cars to Takata inflator recall list

As part of the Takata airbag inflator recall expansion announced by NHTSA earlier this month, Toyota has listed an additional 1.6 million cars that will need to have inflators or airbag assemblies replaced. This brings the total of recalled Toyota, Scion, and Lexus vehicles to 4.73 million. Other automakers will announce their expanded recall lists this week as well. This round of recalls affects some but not all vehicles with the following model names and years: 2009–2011 Toyota Corolla and Matrix 2006–2011 Toyota Yaris 2010–2011 Toyota 4Runner 2011 Toyota Sienna 2008–2011 Scion xB 2007–2011 Lexus ES 2010–2011 Lexus GX 2006–2011 Lexus IS To see if your specific vehicle falls under recall, write down your VIN and go to toyota.com/recall; you can also check any recalls, Takata or otherwise, at safercar.gov/vin. Toyota will inform owners of affected vehicles by mail. Depending on the model, either the inflator or the entire airbag assembly will have to be replaced. Due to the number of vehicles that have already been recalled, it may take some time for the necessary parts to be available. A total of 11 deaths have been attributed to the faulty Takata inflators, and federal investigators now know why the parts are prone to failure. The state of Hawaii was the first to sue the auto supplier, with more states expected to follow. The 17 other automakers are required to announce their additions resulting from the May 4 expansion this week, so expect more of the 35 to 40 million vehicles to be listed soon. Related Video: Image Credit: Reuters Recalls Lexus Scion Toyota Takata airbag recall lexus is toyota sienna toyota 4runner toyota matrix lexus es lexus gx

Here We Go Again: Lexus attacks EVs in new ad [UPDATE]

UPDATE: We got a comment from founding member of Plug In America Paul Scott on this ad. It's available below. The last time Lexus attacked plug-in battery vehicles in an ad, it had to apologize. The company is remaining on message, though, and has revisited a hybrid-vehicle advertising campaign that implies that driving a battery-electric vehicle is a big waste of time, because of all the charging you need to do. With the new spot, Lexus once again raised hackles of plug-in vehicle advocates because, once again, the accuracy is questioned. "The ad's message was that a consumer could [drive] a vehicle with advanced technology today, without sacrifice or change in habit." – Lexus spokesman Brian Bolain Lexus is running print ads (click to enlarge) in publications like Wired poking fun at EVs, the International Business Times says. Lexus highlights range anxiety in the spot, comparing the amount of time it takes to fully recharge an EV – and the idea that air conditioning and using the radio can shorten an EV's range – to the fun of just driving a Lexus. "The [print] ad was merely intended to paint a picture of life with a hybrid, which is basically no different from life with a traditional gas-powered vehicle, versus life with an EV, which can have challenges or at least uncertainties," Lexus spokesman Brian Bolain told AutoblogGreen. "In other words, at its core, the ad's message was that a consumer could participate in driving a vehicle with advanced technology today, without sacrifice or change in habit." The campaign picks up where Lexus's previous anti-EV campaign left off this spring. A website promoting Lexus's hybrids (and parent company Toyota's H2 vehicles) claimed that there was a hydrogen refueling infrastructure set up in 20 US states (not anywhere close to true). Plug-in advocates were also quick to note that higher-powered EV recharging systems can allow a plug-in to be recharged in far less than the four hours the Lexus site claimed. Of course, Toyota has a lot more skin in the game when it comes to hybrids and, starting next year, hydrogen fuel-cell vehicles than it does for plug-ins. Through August, the company sold just 842 RAV4 EVs and about 11,500 Toyota Prius Plug-in Hybrids in the US. That compares to almost 19,000 Nissan Leaf EVs and a Tesla Model S count that's likely close to that figure as well (Tesla breaks out neither monthly sales numbers nor US-only sales for the Model S).