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Toyota makes $100M investment to boost Indiana Highlander production

Toyota has announced that it will be making a $100 million investment in its Princeton, IN factory in a bid to increase production of its popular Highlander CUV. The move will create 300 new jobs by 2016 and increase the total number of crossovers the plant can produce by 30,000.
Toyota currently builds the Highlander, alongside the fullsize Sequoia, at Toyota Indiana's West Plant. The additional capacity, though, will be sent to the East Plant, which is currently responsible for production of the recently refreshed Sienna minivan.
"The Highlander has been a great product for our plant," Toyota Indiana President Norm Bafunno said in a statement. "Establishing Highlander as the 'bridge vehicle,' as we call it, between the East and West plants increases our ability to meet customer needs for our outstanding products. This exciting news is a true testament to the capability of our hard-working and dedicated team members."

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."

Hyundai tops Toyota in annual CarMD Vehicle Health Index

CarMD has released its third annual Vehicle Health Index, which for the 2013 tracked the frequency and cost of repairs for "check engine" problems of 119-million vehicles built between the 2003 and 2013 model years. For the first two years of the index, Toyota ranked at the top of the list, but this year's results see Hyundai moved to number one, pushing Toyota down a spot.
The Korean automaker's rise to the top has been "fueled by its low repair frequency," according to CarMD. Toyota is second to Hyundai in lowest repair frequency, but Toyotas also have the highest average cost of repair. (Interestingly, General Motors vehicles have the lowest average.) Both Toyota's and Hyundai's manufacturer "health" ratings suffered this year, but Toyota took a bigger hit, which also is what helped Hyundai achieve the top ranking.
While Hyundai is the top manufacturer in the index, the 2012 Toyota Camry is the top vehicle. The best-ranking Hyundai was the 2010 Elantra (behind three Nissan models and four Toyotas), which took the number eight spot. Hyundai has six other vehicles in the top 100.