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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."

West Coast labor dispute hampers Japanese automakers' US plants

The ongoing labor dispute between the International Longshore and Warehouse Union and port owners along the West Coast is starting to affect more Japanese automakers building vehicles in the US. The issue already forced Honda and Subaru to take the expensive option of airlifting some parts into the US weeks ago, and according to USA Today, Toyota and Nissan have begun doing so, as well. The choice hasn't been cheap, though, and Subaru's chief financial officer estimated that the decision cost around $60 million more per month than sending components by cargo ship. The effects continue to radiate, according to USA Today, and shortages of some models are possible. Honda is slowing production at its factories in Ohio, Indiana and Canada because the automaker doesn't have enough transmissions and electronics for some vehicles. Toyota already cut back on overtime at some factories. Nissan has only seen a small effect from the issue, though, because of its local suppliers. Dock workers and port owners have been negotiating on a new contract since last year, and the union has organized work slowdowns in response. According to USA Today, the automakers could move shipments to Canada or Mexico, but it would take longer for parts to arrive. News Source: USA TodayImage Credit: Mark Ralston / AFP / Getty Images Earnings/Financials Plants/Manufacturing UAW/Unions Honda Nissan Subaru Toyota shipping port labor dispute

Toyota to sell hot-pink Crown in Japan

Akio Toyoda is doing a pretty decent job at the helm of the Toyota empire. This is the man, after all, that declared that Toyota would get new sports cars, and that they needed to be, not should be, rear-wheel drive. We can respect that. Toyoda is also trying to do away with his company's conservative styling and bring edgier vehicles to market.
Toyota's designers have done just that, although perhaps they went a bit too far. In November, Toyota debuted its fourteenth-generation Crown with a bling-bling fascia that makes Lexus' spindle grille look as conservative as a three-piece suit, and a retina-searing pink paintjob. See, in Japan, the Crown is to Japan's older crowd what the 2002 Buick Park Avenue is to America's senior citizens. As Automotive News reports, the idea with the pink was to draw attention to the grille, but it was originally intended as a debut item, only.
Now, Toyota is actually planning to offer the electric fuchsia Crown for sale to regular buyers. Interested parties will have from September 1st to September 30th to place an order for the big sedan. According to the AN report, Toyoda said to reporters at the debut, "My initial reaction was: 'You're kidding! Please, not pink." We wish they were kidding.