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Toyota issues multiple recalls for 6.4 million vehicles worldwide

It looks like 2014 may go down as the year of recalls. We were already at a record pace, and now it seems Toyota is recalling 6.39 million vehicles worldwide, including about 30 of its models for a variety of problems. None of the faults have caused any injuries or fatalities, but there have been two reports of fires caused by a defective engine starter motor.
Toyota's numbers show 1.772 million vehicles being recalled in the US, but that includes some overlap because the Yaris is being repaired for multiple faults. According to The Detroit News, there are 2.36 million affected models in all of north North America, 1.09 million in Japan and 810,000 in Europe, plus smaller numbers in other regions.
Among the vehicles recalled in the US are 1.3 million units of the 2009-2010 Corolla, Matrix and Tacoma, the 2008-2010 Highlander, the 2006-2008 Rav4 and 2006-2010 Yaris. The problem is that the driver's airbag module is attached via a spiral electrical cable. The connections on the cable can be damaged when the steering wheel is turned, which deactivates the airbag and causes the airbag warning light to come on. Toyota is replacing the cable with an improved part, but it's still making preparations to begin the repair. The company is sending affected owners notifications in the mail. According to The Detroit News, an unspecified number of Pontiac Vibe vehicles are also included in this recall because it shares the part with the Matrix.

Toyota highlights JDM Mark X with special Yellow Label edition

Never heard of the Toyota Mark X? That's because the Japanese automaker only sells it in its home market (and in China as the Reiz). It's a rear-drive (or all-wheel-drive) sports sedan about the size of a Lexus IS, whose existence is probably why Toyota will never bring the Mark X to North America. The current model has been on the market since 2009, but Toyota is rolling out a series of updates - including the new Yellow Label model pictured here.
Available on the 250G, 250G Four and 250G S trim levels, the Yellow Label gets a special shade of Awaken Yellow paint (though it can be had in black, white or silver as well), with an interior decked out in either yellow or black. It also gets piano lacquer trim, yellow stitching, pink gold accents, special tread plates and other interior equipment upgrades, as well as a unique set of alloys. All of which makes the Toyota Mark X Yellow Label perfect for recreating scenes from Kill Bill without the need to squeeze into yellow leathers. (In fact we wouldn't be surprised to see Toyota doing just that for a promo clip.)
Power comes from a 2.5-liter V6 (and not the larger 3.5 available on the 350S model) channeled through a six-speed automatic to either the rear wheels or all four. Pricing ranges between 2.8 and 3.1 million yen (~$26-30k), representing a premium of about 106k yen ($1k) over non-yellow models. Toyota operates four distinct dealer networks in Japan, and the Mark X is sold through Toyopet stores.

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."