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Five automakers now being investigated by NHTSA for airbag woes

It appears that Toyota's renotification to owners of recalled vehicles from last year is just the tip of the iceberg for what could potentially be a much larger industry-wide recall. The National Highway Traffic Safety Administration is opening a preliminary evaluation investigation into roughly 1.1 million vehicles from Chrysler, Honda, Mazda, Nissan, Toyota and parts supplier Takata regarding faulty airbag inflators in several models.
NHTSA has received six reports - three directly, two from Takata and one from Toyota - of vehicles with ruptured airbag inflators from 2002-2006, which resulted in three injuries. So far, all six incidents have occurred in high humidity areas like Florida and Puerto Rico. According to Toyota's latest recall announcement, the inflators may have an improper propellant that could cause it to rupture in a crash and the bag to deploy abnormally.
This new investigation follows a previous recall from April 2013 of about 3.4 million vehicles worldwide for the airbag inflators from Takata. As Autoblog reported, Toyota jumpstarted the new situation when it found that the original list of serial numbers for the faulty part was incomplete and discovered more cars in need of replacement. Honda and Nissan told us that they were investigating whether further models would need called in again as well. Mazda told Autoblog: "Regarding the current Takata situation, we're working closely with NHTSA and investigating the situation, but nothing else to report at this time." Chrysler Group responded to us with the statement: "Chrysler Group engineers are conducting the appropriate analysis. The Company will cooperate fully with the National Highway Traffic Administration."

Editors' Choice: Top Five 2015 Frankfurt Motor Show Debuts

Consider the 2015-16 auto show season officially kicked off. The Frankfurt Motor Show offered a great look at the newest crop of production cars and conceptual machines, and brought some old favorites back into the spotlight for a closer look. (The Alfa Romeo Giulia, for example, debuted in June, but this was the first time most of us saw it.) Now that the dust has settled and we're all on flights back to the US, our editors cast their votes for their personal favorites from the Frankfurt show. These are the cars we truly loved seeing the most. But unlike other shows, there was no one runaway winner – all of the Top Five received positive praise from our team. We won't spoil the results, though. Scroll down to see what we liked most from this year's Frankfurt expo. 5th Place – MERCEDES-BENZ IAA CONCEPT View 12 Photos MIKE AUSTIN: The clean lines on this concept have me excited for a more elegant beauty to future Mercedes-Benz vehicles. Next to the Concept IAA, the lovely S-Class Coupe looks like an overstyled barge. DAVID GLUCKMAN: Yeah, the extendable rear is neat and all, but I'm more interested in the front-end styling of this one. It looks like the Tron version of a 300SL, in a good way. I'm hopeful it portends the future of Mercedes design. STEVEN EWING: I was super impressed when Mercedes said that, with the rear end extended, this concept has a drag coefficient of just 0.19. That's crazy aerodynamic. I'm not head-over-heels about the styling, but I think the lessons learned from this concept are really important, and will play a huge role in the future of Mercedes' products. 4th Place – ALFA ROMEO GIULIA View 15 Photos SEYTH MIERSMA: I can hardly express how in love with this car I am. The styling feels creative, modern, and evocative, without going over the top. The proposed performance is spectacular. And the Alfa badge speaks to a legacy of romantic motoring. DAVID GLUCKMAN: Pretty Italian car makes big promises and will probably deliver on about three quarters of them. I think that will still be enough for me. JEREMY KORZENIEWSKI: I'm really intrigued by the Giulia. It looks great, sounds awesome, and I'm expecting it to have a load more character than its German rivals. I hope I'm not disappointed. 3rd Place – JAGUAR F-PACE View 15 Photos GREG MIGLIORE: It's the first SUV for Jaguar, and I think they nailed the design, capability, and electronics. It's the right car at the right time.

Honda's Acura NSX masterstroke: building the factory in Ohio

When Honda announced it was going to build its NSX supercar in Ohio instead of Japan, it caught everybody in the industry by surprise. No one expected this proud Japanese company to build its most technologically advanced sports car anywhere but in its home country. Now Honda has a supercar production facility in rural Ohio that would be the envy of any Formula One team. The people at Honda call it the PMC, but its official name is the Performance Manufacturing Center. It's a building that started out as a shipping facility for suppliers, but Honda invested $70 million to transform it into a showcase facility that will build the NSX. Honda benchmarked the assembly operations at Ferrari, Lamborghini, McLaren, and Bentley before work began on its facility. The 200,000 square-foot building will also double as a customer reception center – Honda will open the doors for customers to come see their car being built. It's also going to offer them high-speed test drives at the gigantic Transportation Research Center just down the road. No one expected this proud Japanese company to build its most technologically advanced sports car anywhere but in its home country. Inside, the layout is wide open and well lit. There are no stripes or lines on the floor and none of the different departments are walled off. This creates a more welcoming appearance and lets you get a comprehensive view of the entire process at a glance. And with an eye towards future lessons learned, most of the equipment is of a modular design that can be easily reconfigured or moved. The body shop and paint shop are enclosed by glass walls so that anyone can see what's going on inside. And while you'll see some automation here and there, the idea was to achieve a blend between man and machine, not to try and automate everything. This is a low-volume facility with production targeted at only eight to ten cars a day. The plant runs four days a week with one ten-hour shift. Don't expect to see rows of new NSXs parked on any dealer's lot. The car will only be built to order. Honda is obsessed with ensuring the NSX is built to the most exacting quality standards. The plant people pored over the JD Power Appeal study to determine what supercar customers care about the most, then looked at which aspects of that directly tie into manufacturing. They developed their quality control strategy with three goals in mind. First, they wanted to build everything right the first time with no adjustments.