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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."

Toyota reveals latest autonomous tech test bed

Toyota revealed its latest autonomous technology effort Friday, a sophisticated Lexus LS 600hL prototype that showcases its plans to advance in the emerging field. The Lexus is the first developed entirely by the company's in-house Toyota Research Institute and it will focus on the car's ability to learn and see behavior on the road. Toyota is showing the car at the Prius Challenge event at Sonoma Raceway. The Lexus uses Lidar, radar, and sensors, which potentially reduce reliance on mapping. The prototype advances Toyota's last concept vehicle shown at the Consumer Electronics Show in 2013. This one is said to be more flexible and it will focus on Toyota's two autonomous tech pillars, called Guardian and Chauffeur. Guardian is meant to improve safety features, while Chauffeur moves toward full autonomy. "We believe Guardian can probably be deployed sooner and more widely than Chauffeur, providing high-level driver-assist features capable of helping mitigate collisions and save lives, sooner rather than later," Toyota Research Institute Gill Pratt said in a statement. Related Video: Green Lexus Toyota Autonomous Vehicles Luxury Sedan lexus ls

Toyota World's Top-Selling Carmaker For Second Year

Toyota remained the top-selling automaker for a second year in a row, beating U.S. rival General Motors by some 270,000 vehicles in 2013, and set an ambitious target to sell more than 10 million vehicles this year. That would mark a milestone as no automaker has ever topped annual worldwide sales of 10 million. Toyota Motor Corp. said Thursday it sold a record 9.98 million vehicles worldwide last year, up 2 percent from the previous year. The Japanese automaker has made an impressive comeback from an earthquake and tsunami that devastated northeastern Japan in 2011, damaging auto suppliers and hobbling production. Toyota also outlined plans to sell 10.32 million vehicles and produce 10.43 million vehicles in 2014. General Motors Co. sold 9.71 million cars and trucks worldwide last year, outselling Volkswagen AG of Germany at 9.5 million. Toyota recaptured the global sales crown in 2012 from GM, which had been the top-selling carmaker for more than seven decades until being surpassed by Toyota in 2008. Toyota, which makes the Camry sedan, Prius hybrid and Lexus luxury models, had strong sales growth last year in overseas markets, although sales fell in long stagnant Japan. Toyota's U.S. sales totaled nearly 2.24 million vehicles, up 7 percent from the previous year. Its China sales were also strong, surging 9 percent to 917,000. Toyota remained optimistic about prospects this year for both regions, expecting sales to grow 3 percent in the U.S. to 2.3 million vehicles, while adding 20 percent in China sales to 1.1 million. The company was typically low-key about the bragging rights for being No. 1, reiterating its comments from previous years that it was merely making one car at a time to appeal to global consumers. GM has also expressed similar sentiments, but being the top seller is a key morale booster for the employees and related companies. The healthy results at the three rivals reflect the momentum of growth in the auto industry. Toyota has undergone tough times in recent years, such as a massive recall fiasco in the U.S. involving more than 14 million vehicles for sticky gas pedals, faulty floor mats, problematic brakes and many other defects, spanning several years from 2009. Related Gallery AOL Autos Test Drive: 2014 Toyota Highlander Toyota Ownership sales selling