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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 RAV4 "Adventure" brings the butch

Just last week, your humble author had a 2013 Toyota RAV4 in his garage, and he couldn't help noting that even in mid-level XLE trim, its aesthetics lacked oomph, due in large part to its cheap-looking black bumpers and airy-looking wheel wells. Judging by the RAV4 "Adventure" on display at the Geneva Motor Show, someone at Toyota must've been thinking the same thing.
With Japan's biggest automaker understandably focused on bigger reveals, information on this butched-up softroader has proven to be hard to come by, with no press materials whatsoever. We don't even know if this is a pure concept or if it's actually being considered for production. Either way, we approve. The 20-inch dark-finish alloys probably don't do much for ride quality, but they certainly look nicely aggressive, as does the new lower fascia with its prominent lower lip. Other changes include beefier wheel arches, side rails, headlamps with integrated LEDs, twin-element fog lamps and mesh grille inserts. All of the changes are quite well integrated - enough so that the Adventure largely avoids looking like a SEMA refugee in person.

Toyota offered $146.5 million to build Lexus ES in Kentucky

Toyota posted a media advisory yesterday saying that Akio Toyoda, president of Toyota, and Jim Lentz, CEO of Toyota North America, would be making a production announcement tomorrow in New York City, and Automotive News reports that the automaker will be announcing a plan to domestically produce the Lexus ES. According to the report, numerous plants are competing to build the ES in North America, and the State of Kentucky has offered the automaker up to $146.5 million to build the luxury sedan at the Georgetown, KY assembly plant.
If Georgetown gets the ES, which has been built in Japan since its debut in 1989, it would be built alongside the Toyota Camry, which is somewhat ironic since in our review of the 2013 Lexus ES350, we wrote that this ES finally says "goodbye to its Camry roots." In order to get the whole amount offered, the article states that Toyota would have to invest $531.2 million and hire 570 full-time workers at the plant, which doesn't sound all that unreasonable since the plant would require an additional 50,000 units of annual production, not to mention the fact that the Georgetown facility is already at its capacity for building the Camry.