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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 Camry could lose No. 1 sedan spot next year [w/video]

Eleven months after Toyota claimed the 2012 sales crown a couple of months early thanks to the Camry, the headlines this year have been quite a bit different to last. Even though the Camry remains the best selling car so far in 2013 and its volume has increased year-on-year, it has lost market share due to the 20-percent sales explosion in the midsize segment. That means people are buying more of the competitor offerings like the Honda Accord, Nissan Altima and Ford Fusion - the Altima, in fact, outsold the Camry by 100 units in March.
In July it was reported that Toyota was upping Camry incentives and fleet sales to keep its lead and that dealer inventory was climbing as, again, competitors got better at fighting the champion. In August Ford doubled down on production of the Fusion, adding a line in Flat Rock, MI to keep up with demand.
Bloomberg has a report looking at the numbers behind the Camry's dominance, as well as what appears to be a recorded group interview with Toyota USA CEO Jim Lentz, and wonders aloud whether the Camry will be able to hold its top spot in 2014. Barring catastrophe it has this year locked up, being more than 30,000 sales ahead of the next-best seller as of the end of August, but it has done so with higher incentives and lower transaction prices than its competitors. According to Strategic Vision the Camry's consideration rate among consumers has also declined by a percentage point, while the consideration rate for the Accord and Fusion has increased by one point and two points, respectively.

Ford tumbles to second worst in Consumer Reports reliability survey, list dominated by Japanese [w/video]

It's no secret that MyFord Touch has had its share of problems since being introduced, but the most recent reliability survey from Consumer Reports shows just how much this infotainment system has affected Ford. Just two years ago, the automaker was in the top 10 for the institute's reliability rankings, but since then, it has tumbled to the second-lowest rung just above dead-last Jaguar. In addition to MyFord Touch, CR also attributes a handful of new products that have had issues right out of the gate.
Compiled from 1.2 million subscriber surveys, this year's auto reliability survey heavily favors Japanese automakers, with eight of the 10 spots hailing from Japan. Toyota brands grabbed the top three spots (Scion, Toyota and Lexus - in that order) with Mazda, Subaru, Honda and Acura filling the next four spots. The only non-Asian automaker cracking the top 10 was Audi at number eight.
Audi climbed a total of 18 spots from last year, and Cadillac and GMC round out this year's top gainers breaking into the top 15. Helping Cadillac's upward movement, the CTS Coupe was named the most reliable domestic car. Lincoln, Volvo and Chrysler join Ford on this year's biggest loser list.