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J.D. Power study sees new car dependability problems increase for first time since 1998

For the first time since 1998, J.D. Power and Associates says its data shows that the average number of problems per 100 cars has increased. The finding is the result of the firm's much-touted annual Vehicle Dependability Study, which charts incidents of problems in new vehicle purchases over three years from 41,000 respondents.
Looking at first-owner cars from the 2011 model year, the study found an average of 133 problems per 100 cars (PP100, for short), up 6 percent from 126 PP100 in last year's study, which covered 2010 model-year vehicles. Disturbingly, the bulk of the increase is being attributed to engine and transmission problems, with a 6 PP100 boost.
Interestingly, JDP notes that "the decline in quality is particularly acute for vehicles with four-cylinder engines, where problem levels increase by nearly 10 PP100." Its findings also noticed that large diesel engines also tended to be more problematic than most five- and six-cylinder engines.

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 says freezing temps pose zero problems for fuel cell vehicles

Hydrogen-powered fuel cell electric vehicles are not afraid of one thing – freezing cold weather. That's the latest from two companies that have been driving the cars in frostbite temperatures in the Northeast recently. Proton Onsite runs a fleet of 10 Toyota FCHV-adv fuel cell vehicles out of its Connecticut headquarters and discovered that the snow and three-degree temperature didn't restrict range. Mark Schiller, Proton vice president of business development, said in a statement that, "I went out to my Toyota FCHV-adv and brushed off a foot of snow before starting the car right up. No problem." While electric vehicles can have their driving range reduced in extreme temperatures (but not always), Proton Onsite hasn't seen that happen in the Polar Vortex. They're performing flawlessly in freezing temperatures even with the heaters blasting, and are continuing to hit their range of about 300 miles, Schiller said. Air Products, based on Allentown, PA, has had a similar experience. The FCHV-adv has had great performance under harsh conditions, according to Nick Mittica, commercial manager, hydrogen energy systems. Employees drove the fuel cell vehicle during one of Pennsylvania's worst winters in recent memory and, you guessed it, "No problem." Toyota says that has put its fuel cell fleet through the wringer, logging millions of miles over the last decade, to make sure performance can be delivered within extreme weather conditions. Toyota engineers spent weeks testing cold weather start up, performance and durability up in Yellowknife, Canada. Temperature can reach -30 degrees Celsius (-22 degrees Fahrenheit) at that location. On other end of the scale, Toyota was able to verify that its FCVs can handle driving through heat in Death Valley national park. We heard the same from Mercedes the other day, too. Extreme weather functionality is apparently something automakers want to make absolutely sure the public doesn't worry about. Jan. 30, 2014 – Record low temperatures have stranded many East Coast drivers, but not those driving a Toyota fuel cell hybrid vehicle. Connecticut-based Proton Onsite, which operates a fleet of ten Toyota FCHV-adv fuel cell vehicles, says that even in single digit temperatures, the FCHV-adv shows no signs of frostbite. "We had another snow storm Tuesday night and this morning the temperature was 3 degrees," says Mark Schiller, Proton vice president of business development.