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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."

Junkyard Gem: 2010 Pontiac Vibe

Just over a month before filing for Chapter 11 bankruptcy in June 2009, General Motors announced that the 83-year-old Pontiac Division would be "phased out" by the end of 2010. Only three Pontiac vehicles were sold as 2010 models in the United States: the Solstice, Vibe and G6 (new G3s were sold here during 2010 but they were all 2009 models, while the G5 was available as a 2010 model only in Canada and Mexico). Today's bit of junkyard automotive history is one of the very last Vibes ever built, found in a yard near Denver, Colorado. This car is significant not just as one of the final vehicles to bear Pontiac badges but also as one of the last cars built by the New United Motor Manufacturing Incorporated GM-Toyota joint venture in California, better known as NUMMI. The NUMMI factory began life as GM's Fremont Assembly, which built its first vehicle (a C-Series pickup) in 1963 and closed in 1982 after building its final vehicle (an Oldsmobile Cutlass Ciera). Rebooted as NUMMI, the first 1985 Chevrolet Nova (an Americanized AE82 Toyota Corolla Sprinter) rolled off the line in December of 1984. A quarter-century and better than eight million vehicles hence, NUMMI shut down production after its last Corolla was finished on April 1, 2010. While there was some noise about the Oakland Athletics building a new stadium on the site at the time, Tesla ended up buying most of the site soon after that. Tesla now builds more vehicles per year there than NUMMI ever did. The Vibe was co-developed with Toyota and based on the same platform as the ninth-generation Corolla. The Toyota Matrix was mechanically identical and was built in Canada, while the Japanese-market version (known as the Toyota Voltz) was built on the same NUMMI line as the Vibe and shipped across the Pacific. The Vibe/Matrix/Voltz got a redesign for the 2009 model year, but few noticed due to all the turmoil in the GM world at the time. The final Vibe was built in August 2009. This car was built in July of 2009, just before the end. It was living in West Texas just prior to coming to Colorado. El Paso is about a ten-hour drive from this car's current location. Once in the Centennial State, it got parked somewhere it shouldn't have been and ended up being auctioned to Pick Your Part. An occupant of this Vibe had time to sample some of the local agricultural products before that happened.

Foreign automakers pay from $38 to $65 per hour to non-union workers

As leaders for the United Auto Workers gather in Detroit for their Special Convention on Collective Bargaining to work out the negotiating stance for this year's new labor agreements with the Detroit 3 automakers, what they most want to do is figure out how to eliminate the two-tier wage scale. However, the lower Tier 2 wage has allowed the domestic automakers to reduce their labor costs, hire more workers, and compete better with their import competition. As it stands, per-hour labor rates including benefits are $58 at General Motors, $57 at Ford, and $48 at Fiat-Chrysler – a reflection of FCA's much greater number of Tier 2 workers. The Center for Automotive Research released a study of labor rates (including benefits) that put numbers to what the imports pay: Mercedes-Benz pays the most, at an average of $65 per hour, Volkswagen pays the least, at $38 per hour, and BMW is just a hair above that at $39 per hour. Among the Detroit competitors, Honda workers earn an average of $49 per hour, at Toyota it's $48 per hour, Nissan is $42 per hour, and Hyundai-Kia pays $41 per hour. The lower import wages are aided by their greater use of temporary workers compared to the domestics. Automotive News says the ten-dollar gap between those foreign camakers and the domestics turns out to about an extra $250 per car in labor, which adds up quickly when you're pumping out many millions of cars. That $250-per-car number is one that, come negotiating time, the Detroit 3 will want to reduce, as the UAW is trying to raise both Tier 1 and Tier 2 wages. Another wrinkle is that the domestic carmakers are considering the wide adoption of a third wage level lower than Tier 2. Some workers who do minor tasks like assembling parts trays kits and battery packs already make less than Tier 2, but the UAW will be quite wary about cementing yet another wage scale at the bottom of the system while it's trying to fight a bigger battle at the top. News Source: Automotive News - sub. req., BloombergImage Credit: AP Photo/Erik Schelzig Earnings/Financials UAW/Unions BMW Chevrolet Fiat Ford GM Honda Hyundai Kia Mercedes-Benz Nissan Toyota Volkswagen labor wages collective bargaining labor costs