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Toyota expands airbag recall to 2.27M vehicles worldwide

Was your Toyota inspected under the company's recall campaign for faulty airbag inflators last year? You might have another trip ahead to have it repaired again. The automotive giant says that it found "the involved serial numbers provided by the supplier were incomplete, and did not include all of the potentially involved inflators," according to its official announcement. That means more replacements are needed.
Toyota's April 2013 inflator recall covered the Corolla, Matrix and Tundra from the 2003 and 2004 model years, the Sequoia from 2002 to 2004 and the Lexus SC 430 from 2002 to 2004. At the time, the company said it would need to inspect about 510,000 vehicles in the US but only expected to replace around 170,000 inflators.
However, the latest announcement increases that figure to about 766,300 vehicles in the US. Toyota spokesperson Cindy Knight told Autoblog that the new amount is the combination of owners who need to have their vehicle looked at again and those who didn't come in for the initial recall. The company learned about the problem when Takata, the supplier, provided it with an improved list of the faulty part's serial numbers. According to The Detroit News, the latest recall affects about 2.27 million vehicles from them worldwide. Knight said owners would receive notification of the problem around the end of the month but repairs would come in phases because the automaker doesn't have all of the necessary parts at the moment.

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.