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Toyota to suspend 18 assembly lines as production restarts post-quake

TOKYO - Japanese manufacturers began restarting production at plants in the country's quake-hit northeast, but Toyota Motor Corp said it plans to idle 18 assembly lines for a few days next week due to a shortage of parts from suppliers. It had suspended operations at three factories due to the quake and sees lost production of 20,000 units due to the stoppages. Toyota has already cut its global production target due to the ongoing chip shortage. The suspension will cut heavily into Toyota's domestic production. Impacted product lines include the Toyota RAV4, Land Cruiser, Harrier and Yaris and virtually every Lexus. Toyota did not say whether these shutdowns could extend to U.S.-based production lines, but the possibility exists if they receive parts from the same suppliers.  On one hand, the limited damage caused by the magnitude 7.4 temblor has highlighted Japan's success in building resilience against the frequent tremors that shake the archipelago. But the quake has sparked concerns of further disruptions to a pandemic-hit supply chain for precision components vital to electronics and autos production and in which Japanese manufacturers play a leading role. Murata Manufacturing Co Ltd, the top global supplier of ceramic capacitors used in smartphones and cars, said it restarted production on Friday at two stopped plants with the remaining two idled plants to restart next week. A fire that broke out at a factory which produces chip inductors caused some damage to equipment. Renesas Electronics Corp, which makes nearly a third of the microcontroller chips used in cars globally, said it has restarted production after stopping it at two factories with a partial stop at a third. All three factories, including the Naka factory where fire broke out last year, are expected to return to pre-quake capacity by Wednesday, Renesas said. Power has mostly been restored across the northeast, which suffered Japan's biggest earthquake 11 years ago. Areas of Tokyo lost power for nearly three hours after the latest quake, in which three people died and 183 were injured. The blackout has forced the disposal of some COVID-19 vaccines held in cool storage, the Yomiuri newspaper reported. Tech conglomerate Sony Group Corp is in the process of gradually restarting production at three factories in the quake-hit area, a spokesperson said.

LA Design Challenge invokes biology for 2025 concepts [w/poll]

Participants in the annual LA Design Challenge always manage to come up with edgy, wacky designs for future vehicles, but with a theme of "Biomimicry and Mobility: 2025" this year's crop of cars might be the quirkiest we've ever seen. As usual, automotive designers from around the world participated in this year's competition, and all the designs will all be unveiled next week during the LA Auto Show with a winner being announced on November 21.
Chinese automakers made a strong showing with Qoros, SAIC Motor, JAC Motors (the company responsible for the Ford F-150 clone) and Changfeng all bringing interesting takes on the biology, human intelligence and sustainability theme. One of the more innovative ideas among these automakers is the Qoros Silk Road System allows autonomous vehicles to drive in packs similar to how ants travel. Speaking of ants, the SAIC Motor Mobiliant (shown above) gets its design from the shape of an ant's body, and, like the insect, it can climb building acting as a personal elevator as well. The JAC Motors design also merges vehicle and building design, while the Changfeng LaBrea inspired by the design of muscle fibers.
Other entrants include Subaru and US-based design teams for BMW, Toyota and Mazda. BMW's duo of concepts mimic plant and animal life. The LA Subways concept acts as a submersible, single-person vehicle to take advantage of the LA river, with a shape similar to an Ocean Sunfish. The Sustainable Efficient Exploratory Device (SEED) imitates the shape of a seed pod, and uses propulsion methods inspired by a shark, dragonfly and a water bug. Mazda's Auto Adapt might be the most car-like concept of the bunch, while the Subaru Suba-Roo and the Calty-designed, Toyota e-grus are the most mind-blowingly awesome.

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."