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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."

Japan may aid carmakers facing U.S. tariff threat

TOKYO — Japan is considering giving carmakers fiscal support including tax breaks to offset the impact from trade frictions with the United States and a sales-tax hike planned for next year, government sources told Reuters on Wednesday. Going into a second round of trade talks with the United States on Sept. 21, Japan is hoping to avert steep tariffs on its car exports and fend off U.S. demands for a bilateral free trade agreement that could put it under pressure to open politically sensitive markets, like agriculture. "If the trade talks pile pressure on Japan's car exports, we would need to consider measures to support the auto industry," a ruling party official said on condition of anonymity because of sensitivity of the matter. The auto industry accounts for about 20 percent of Japan's overall output and around 60-70 percent of the country's trade surplus with the United States, making it vulnerable to U.S. action against Japanese exports. Japan's biggest automakers and components suppliers fear they could take a significant hit if Washington follows through on proposals to hike tariffs on autos and auto parts to 25 percent. Policymakers also worry that an increase in the sales tax from 8 percent to 10 percent planned for October 2019, could cause a slump in sales of big-ticket items such as cars and home. Prime Minister Shinzo Abe has twice postponed the tax hike after the last increase from 5 percent in 2014 dealt a blow to private consumption, which accounts for about 60 percent of the economy. To prevent a pullback in demand after the tax hike, the government may consider large fiscal spending later when it draws up its budget for next year, government sources said. "One option may be to greatly reduce or abolish the automobile purchase tax," one of the government sources said. The government is also considering cuts in the automobile tax and automobile weight tax to help car buyers, the source added. Reporting by Izumi Nakagawa and Tetsushi KajimotoRelated Video: Image Credit: Getty Government/Legal Isuzu Mazda Mitsubishi Nissan Subaru Suzuki Toyota Trump Trump tariffs trade

Toyota creates GT86 concept inspired by Initial D

Everyone has a favorite movie or TV car of their youths. The love of these cars can ignite a lifelong passion for automobiles. Some lust for the sharp, stainless steel DeLorean DMC-12 from Back to the Future or the decked-out Aston Martin DB5 from Goldfinger. For anime and manga fans, it's the panda-colored Toyota AE86 Sprinter Trueno from the Initial D manga and anime series. Toyota, recognizing the significance of the that car, meticulously reimagined it for a modern audience, basing it on the UK market GT86. The GT86, sold in the United States as the Scion FR-S and soon to be rebadged as the Toyota 86, is considered by some to be the spiritual successor to the rear-wheel-drive AE86 Corolla from the 1980s. Both are reasonably affordable, lightweight cars with a propensity for oversteer. The original AE86 from Initial D was a highly modified but realistic drift machine. The amazing feats of that tofu delivery car as it raced everything from Mazda RX-7s to a Honda S2000 turned the little Toyota into a cult icon. That AE86 itself was inspired by the personal vehicle of Japanese racing driver Keiichi Tsuchiya. Tsuchiya served as both an inspiration and supervisor for Initial D. Many of the modifications on the Initial D car, like the TRD carbon-fiber hood and Fujitsubo exhaust, car were exactly the same as Tsuchiya's real-life vehicle. Toyota is no stranger to crafting modern incarnations of classic vehicles. Last year the company created a Back to the Future Tacoma. Toyota's Initial D concept car uses the same parts wherever possible. Like the original, it has a carbon-fiber hood, Fujitsubo exhaust, and black Watanabe F8 wheels. The suspension, lights, and body have all been modified. Even small details like the engine cover and door handles were modified to recall the fictional car. The end result is a fantastic creation that pays great homage to the original. Toyota went as far as hiring UK manga artist Sonia Leong to design a series of backdrops that place the car in the same action shots as the original series. While this one-off vehicle is just a concept, most of the parts are available to purchase for fans who may be inspired to create their own version. Toyota's concept will be on display at various motoring shows across the UK this summer. Related video: Featured Gallery Toyota Initial D GT86 TV/Movies Scion Toyota Coupe toyota gt86 toyota 86