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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."

Japanese automakers ramping production for renewed American sales

The 2011 earthquake and tsunami that struck Japan took quite the toll on the automotive industry in that nation. Not content to lean on that tragedy as excuse for slagging sales, the Japanese automakers are planning on a major production expansion in North America. The aim is to reclaim the market share lost from the Tsunami-based dip, and overcome a dollar/yen exchange rate that makes exporting to America unprofitable.
Following the Tsunami, Japanese automakers ramped up production in their North American facilities to compensate, but according to Automotive News, Nissan, Honda and others have all reported plans for still-further increased production in the year ahead. As part of this ramp-up, Mazda will open a facility in Salamnca, Mexico before March of 2014. Part of that increase in output is 50,000 units of a Toyota-badged compact car, which Mazda will produce.
Other Mexican production facilities opening include a Honda plant, which will open in Spring 2014 in Celaya, and a Nissan plant, set to open later this year in Aguascalientes. Nissan also said that it will need another plant in North America within the next five years. According to Nissan Boss Carlos Ghosn, the company aims to raise its stake in the US market from 8 percent to 10, and adding production will help achieve that goal. Even Mitsubishi is aiming to boost production at its Normal, Illinois plant. Production of the Outlander Sport is currently at 50,000, which Mitsubishi wants to raise to 70,000.

Toyota, Nissan, Honda will work together on hydrogen filling stations

Japan's own version of the Big Three is taking on a transportation effort that's a far cry from the large-engined history of General Motors, Ford and Chrysler. In fact, Toyota, Nissan and Honda are looking to do their part – and maybe a little more – for the environment by working together to collaborate on accelerating the deployment of hydrogen fuel delivery in Japan. More refueling stations means more convenience for prospective hydrogen fuel-cell vehicle owners. Toyota says the specifics, including investment amount and the number of stations to be deployed, will be "determined at a later date." Still, the effort dovetails with that of the Japanese government. That government announced a so-called Strategic Road Map for Hydrogen and Fuel Cells last June and subsequently said it would start offering about $20,000 worth of incentives for fuel cell vehicle buyers. In December, Toyota started selling its first mass-produced fuel cell vehicle, the Mirai, in Japan and said it would almost triple production to 2,000 vehicles in 2016 from 700 this year. Last month, the Tokyo government began talks with Toyota and Honda to collaborate on ensuring that there'd be at least 6,000 fuel-cell vehicles on Japan's roads in time for the 2020 Summer Olympics in Tokyo. Tokyo officials are looking to have 100,000 fuel-cell vehicles on the city's roads by 2025. Check out Toyota's press release below. Toyota, Nissan, and Honda to Jointly Support Hydrogen Station Infrastructure Development Toyota Motor Corporation, Nissan Motor Co., Ltd., and Honda Motor Co., Ltd. have agreed to work together to help accelerate the development of hydrogen station infrastructure for fuel cell vehicles (FCVs). Specific measures to be undertaken by the three manufacturers will be determined at a later date. For hydrogen-fueled FCVs to gain popularity, it is not only important that attractive products be launched-hydrogen station infrastructure must also be developed. At present, infrastructure companies are making every effort to build such an infrastructure, but they face difficulties in installing and operating hydrogen stations while FCVs are not common on the road. Following the formulation of its Strategic Road Map for Hydrogen and Fuel Cells in June 2014, the Japanese government has highlighted the importance of developing hydrogen station infrastructure as quickly as possible in order to popularize FCVs.