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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 Recalling 516,000 Vehicles In Three Recalls

Toyota said Thursday it's recalling 516,000 vehicles worldwide - including 430,500 in the U.S. - for three separate safety problems, including brakes that can activate without warning. The company said it has no reports of accidents or injuries due to the defects. In all three cases, the company will alert owners and dealers will repair the issues for free. The largest recall, of 450,000 Sienna minivans from the 2004-2011 model years, targets vehicles sold in cold weather areas. Toyota said road salt can corrode the spare tire carrier under the vehicle and the tire can fall off. Siennas from the 2004-2010 model years were for the same issue in 2010, and a splash protector and anti-rust protection were applied. But the company says the splash protector can fall off and rust can still occur. The recall involves 370,000 minivans sold in the U.S., 80,000 in Canada and 400 in Europe. Also recalled Thursday were: - 16,000 Lexus GS 250 and 350 sedans from the 2013 model year because a manufacturing defect can cause the brakes to activate without warning, and without turning on the brake lights. Most of the vehicles - 10,500 - were sold in the U.S. Also included are left-hand-drive sedans sold in Canada, China and Europe. - 50,000 Highlander and Highlander hybrid SUVs from the 2014 model year. Toyota says a software glitch may prevent the vehicle from properly calculating the size of the front passenger when determining whether to fire the air bags. The affected vehicles assume the passenger is smaller, so the bags may not fire or they may fire at a lower speed than necessary for a larger passenger. Toyota says most of the affected vehicles - 45,287 - were sold in the U.S. Around 3,400 were sold in Canada and the rest were sold in Mexico and Europe. Related Gallery AOL Autos Test Drive: 2014 Toyota Highlander Recalls Toyota

What's big at the Chicago show | Autoblog Podcast #503

On this week's podcast, Mike Austin and David Gluckman discuss the big debuts at the 2017 Chicago Auto Show. They also recap what they've all been driving lately, and the episode wraps up with Spend My Money buying advice to help you, our dear listeners. And there's an awful Dad Joke thrown in there for you to find. The rundown is below. Remember, if you have a car-related question you'd like us to answer or you want buying advice of your very own, send a message or a voice memo to podcast at autoblog dot com. (If you record audio of a question with your phone and get it to us, you could hear your very own voice on the podcast. Neat, right?) And if you have other questions or comments, please send those too. Autoblog Podcast #503 The video meant to be presented here is no longer available. Sorry for the inconvenience. Topics and stories we mention Jaguar XE Volkswagen Golf R Toyota Highlander Hybrid Chicago Auto Show coverage Used cars! Rundown Intro - 00:00 What we're driving - 01:46 Chicago show preview - 22:58 Spend My Money - 35:36 Total Duration: 52:48 Get The Podcast iTunes – Subscribe to the Autoblog Podcast in iTunes RSS – Add the Autoblog Podcast feed to your RSS aggregator MP3 – Download the MP3 directly Feedback Email – Podcast at Autoblog dot com Review the show on iTunes Podcasts Chicago Auto Show Chevrolet Dodge Jaguar Toyota Volkswagen Truck Hatchback SUV Performance Sedan ford expedition jaguar xe volkswagen golf r 2017 Chicago Auto Show