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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 and Lexus recalling 235,000 hybrid CUVs and sedans over separate issues

When it rains, it pours. Toyota has announced a pair of separate but voluntary North America recalls covering approximately 235,000 vehicles built between 2006 and 2011. The larger of the two recalls targets Toyota's hybridized crossovers, the Lexus RX400h and Toyota Highlander Hybrid. 133,000 units, including 2006-2010 Highlander and 2006-2008 RX crossovers are covered in the campaign. The other recall affects 102,000 IS350 sedans, IS350C convertibles and GS350 sedans built between 2006 and 2011.
With the CUVs, the faults in the parallel circuits of the transistors can cause heat damage in the inverter assembly, triggering an abundance of warning lamps and sending the vehicle into limp mode. The Lexus sedans are being recalled due to loose bolts on the variable valve timing controller. Detected by unusual underhood sounds on startup, the issue can cause the engine to stop while driving. The inverter issue is also triggering similar recalls in Japan and Europe.
At the moment, it's unclear if any of these issues have caused any crashes or injuries. Toyota says it plans to notify owners of the recall via snail mail. Additional information for owners can be found on the recall sites for Toyota and Lexus or by calling Toyota's customer service line, at 1-800-331-4331. Scroll down for the complete recall notice from Toyota.

Recharge Wrap-up: Nissan Leaf top environmental performer, 50,000th Renault Zoe

Renault has produced its 50,000th Zoe electric car. A Frenchwoman named Sylvie took ownership of the milestone vehicle at the Flins plant where it rolled of the line. She says her children helped convince her to buy the all-electric vehicle, which Sylvie intends to use as a daily driver. The Renault Zoe is Europe's best selling EV since its launch in 2013. Renault reports a 98-percent satisfaction rate with the Zoe. Read more in the press release from Renault. Toyota will use a biosynthetic rubber called biohydrin in its engine and drive system hoses beginning in May 2016. Jointly developed by Toyota, biohydrin is a plant-based rubber with a 20-percent reduction in material lifecycle carbon emissions compared to petroleum-based rubber. Toyota plans to use the compound in even more components in the future, including brake and fuel line hoses. Read more from Toyota. So far in 2016, only 27.5 percent of hybrids and EVs are traded in for another electrified vehicle, according to Edmunds. That's down from 38.5 percent in 2015. 33.8 percent of electrified vehicles are traded in for SUVs. Despite the trend of EV and hybrid owners switching back to traditionally powered vehicles, average fuel economy isn't suffering. "This is an economics trend, since today's low cost of gas no longer makes it worth paying the price premium of hybrids and EVs," says Edmunds Director of Industry Analysis Jessica Caldwell. "And there are so many fuel-efficient vehicles on the market today that environmental concerns weigh less than they might have in years past. When you're buying a vehicle that can get over 30 mpg, you can still say you're doing your part to help the environment." Read more from Edmunds. Environmentally, electrified vehicles outperform their conventional combustion counterparts throughout their lifecycle. A study from the Automotive Science Group (ASG) finds that while production of advanced powertrains comes with a greater financial burden, most vehicles make up for it through efficiencies during their use phase. The ASG lists the 2016 Nissan Leaf as its best performer, with 47 percent fewer greenhouse gas emissions than the best-performing conventionally powered car, the Honda Fit. Rounding out the ASG's top five environmental performers are the Ford Focus Electric, Chevrolet Volt, Toyota Prius Two Eco, and Hyundai Sonata Plug-In Hybrid.