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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 Aygo, Citro?n C1 to join Peugeot 108 in Geneva

Just the other day, Peugeot took the wraps off the new 108. But its new city car, like the 107 it replaces, doesn't stand on its own. The 107 was a sister vehicle to not only the Citroën C1 but also the Toyota Aygo. So it should come as little surprise that, while Peugeot was the first to release photos and details on its version, Citroën and Toyota will also be on hand with their own versions when the veils lift on all three at the Geneva Motor Show.
We're expecting the new trio of budget-oriented hatchbacks to bear the fruits of individual efforts to distinguish themselves one from another more than their predecessors, which essentially looked the same save for different badges. But from the teaser image above, we'd venture that the Toyota version will be a further departure from the 108 than the C1 will be.
One way or another we'll have to wait and see, but for now you can view Toyota's teaser clip below, along with the press releases confirming the debut of both in Geneva next month.

119K Toyota Avalon sedans recalled over airbag woes

Toyota has issued a voluntary safety recall for 119,000 2003-2004 Avalon models because in some cases the airbags could inadvertently deploy.
The automaker says that circuits within the airbag control module could be damaged by electrical noise, which could cause the front airbags and seatbelt pre-tensioners to activate. Dealers are going to repair cars by adding an electrical noise filter to the module. Owners will be notified by first class mail.
Toyota Public Affairs Manager Cindy Knight told Autoblog that there was one reported injury caused by the sudden deployment, but there have been no accidents or crashes. The company is currently preparing the parts for dealers now, and the component takes 90 minutes to two hours to install. "We don't believe there are any other affected models," said Knight.