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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."

Recharge Wrap-up: Toyota battery breakthrough, PSA's millionth BlueHDi diesel

Scientists at Toyota have developed battery technology that allows for higher energy density. Using material from hydrogen storage, researchers at the Toyota Research Institute of North America (TRINA) in beautiful Ann Arbor, Michigan have created an electrolyte that works well with a magnesium metal anode. Besides improving energy density for smaller, more powerful batteries, magnesium is also more stable than lithium, making it a safer alternative. Rather than guarding their secret, Toyota is sharing details of this breakthrough in order to advance the technology in hopes of an earlier mass deployment of magnesium batteries. See the video above, and read more in the press release below. Farmdrop – a sort of online farmer's market in the UK – is looking for help naming its electric delivery "vanimals." The Nissan e-NV200 vans are painted and decorated to look like cows, pigs, and chickens. While three of the vans have already been named, fans can suggest their own clever ideas for the rest of the fleet on social media. Those whose names are selected will win a month's worth of shopping on Farmdrop. Cary McCarface, anyone? Read more at the company's website. PSA has built its millionth Euro 6 BlueHDi diesel engine. The automaker builds two diesel engines – a 1.6-liter and a 2.0-liter – at its plant in Tremery, France at a rate of 7,000 engines a day. BlueHDi technology uses three different emissions control mechanisms to filter pollutants out of diesel exhaust, including an oxygen catalyst, an additive filter to remove particulate matter, and a Selective Catalytic Reduction system to reduce NOx. BlueHDi is used in all new Peugeot, Citroen, and DS Euro 6 diesel vehicles. Read more at Green Car Congress. Charging Ahead Toyota Scientists Make Breakthrough on Safer, Smarter Batteries May 04, 2016 ANN ARBOR, Mich. (May 4, 2016) -- For anyone (i.e. everyone) who's ever panicked when their mobile device chirped, "low battery," the future could be far less stressful, thanks to the advanced battery research of scientists at the Toyota Research Institute of North America (TRINA). A new breakthrough involving magnesium batteries may soon open the doors for smaller, longer-lasting batteries for everything from cars to cell phones. What's the Big Deal with Magnesium? Magnesium metal has long been theorized as a much safer and more energy-dense alternative to current lithium battery technology.

Weekly Recap: Toyota wants cars to be your 'close friends' around 2020

Toyota confirmed plans this week to launch autonomous technology in its production cars around 2020. The automaker's version is called Highway Teammate, and it's one element of a broader mobility strategy that includes vehicles communicating with each other and the grid. "Toyota believes that interactions between drivers and cars should mirror those between close friends who share a common purpose, sometimes watching over each other and sometimes helping each other out," the company said in a statement. That sounds utopian, and perhaps a bit cheesy, but it's an acknowledgment that autonomous driving requires more than technology developed in a vacuum. Toyota is looking at its research in a broader context, and dubs its overall strategy the Mobility Teammate Concept. Highway Teammate is the first step. Its test vehicle is a modified Lexus GS, which uses road-mapping data and external sensors to merge or exit highways, change lanes, and maintain safe distances during driving. It's operated on the Shuto Expressway in Tokyo. Toyota has been working on autonomous tech since the 1990s, with the goal of providing mobility for older people and the disabled, as well as lowering the frequency of traffic accidents. Toyota's push comes as an early adopter, Nissan, is hedging on its own deadline to implement the autonomous tech by 2020 due to a lack of firm laws governing self-driving cars around the world. Conversely, Volvo took the landmark step of being the first automaker to accept liability for when its cars will operate in autonomous mode, and urged the US government to set federal guidelines to regulate the technology. OTHER NEWS & NOTES 2016 BMW M4 GTS: Your water-injected, turbo-boosted demon BMW is unleashing its most powerful M4 ever, a 493-horsepower special edition that's road legal yet bred for the track. The company is making 700 copies for sale around the world, and 300 of them will come to the United States. The twin-turbocharged 3.0-liter six-cylinder revs to 7,600 rpm and uses a water-injection technology to cool the intake air and lower the compression temperature. BMW says this allows it to wring more power out of the inline six. The car also uses carbon-fiber reinforced plastic for the roof, hood, engine compartment strut brace, drive shaft, and rear spoiler to reduce weight. The M4 features BMW's organic light-emitting diode taillights, which are said to be an industry first.