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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."

Foreign automakers pay from $38 to $65 per hour to non-union workers

As leaders for the United Auto Workers gather in Detroit for their Special Convention on Collective Bargaining to work out the negotiating stance for this year's new labor agreements with the Detroit 3 automakers, what they most want to do is figure out how to eliminate the two-tier wage scale. However, the lower Tier 2 wage has allowed the domestic automakers to reduce their labor costs, hire more workers, and compete better with their import competition. As it stands, per-hour labor rates including benefits are $58 at General Motors, $57 at Ford, and $48 at Fiat-Chrysler – a reflection of FCA's much greater number of Tier 2 workers. The Center for Automotive Research released a study of labor rates (including benefits) that put numbers to what the imports pay: Mercedes-Benz pays the most, at an average of $65 per hour, Volkswagen pays the least, at $38 per hour, and BMW is just a hair above that at $39 per hour. Among the Detroit competitors, Honda workers earn an average of $49 per hour, at Toyota it's $48 per hour, Nissan is $42 per hour, and Hyundai-Kia pays $41 per hour. The lower import wages are aided by their greater use of temporary workers compared to the domestics. Automotive News says the ten-dollar gap between those foreign camakers and the domestics turns out to about an extra $250 per car in labor, which adds up quickly when you're pumping out many millions of cars. That $250-per-car number is one that, come negotiating time, the Detroit 3 will want to reduce, as the UAW is trying to raise both Tier 1 and Tier 2 wages. Another wrinkle is that the domestic carmakers are considering the wide adoption of a third wage level lower than Tier 2. Some workers who do minor tasks like assembling parts trays kits and battery packs already make less than Tier 2, but the UAW will be quite wary about cementing yet another wage scale at the bottom of the system while it's trying to fight a bigger battle at the top. News Source: Automotive News - sub. req., BloombergImage Credit: AP Photo/Erik Schelzig Earnings/Financials UAW/Unions BMW Chevrolet Fiat Ford GM Honda Hyundai Kia Mercedes-Benz Nissan Toyota Volkswagen labor wages collective bargaining labor costs

Consumer Reports says Ram 1500 tops fuel economy fight [w/video]

Consumer Reports takes its independent vehicle testing procedures seriously. In an era when we have to question the EPA's official ratings thanks to recent re-evaluations from Ford and Hyundai, an independent voice is important. So, when CR says something is the best, it's worth paying attention to. The Ram 1500 EcoDiesel has "about the same fuel-economy numbers that we typically see in a midsized SUV." – Jake Fisher In this case, CR took a look at the fuel economy of the 2014 Ram 1500 EcoDiesel and found that it came out on top of the fullsize pickup truck pack. The Ram did so with 20 miles per gallon overall and 27 mpg on the highway. CR gave the truck a total road test score of 82. The EPA says that the EcoDiesel 1500 gets 28 mpg on the highway, 20 mpg city and 23 mpg combined. Comparing official EPA numbers, the Ram is also the best among trucks in its class. It's nice when people agree on something. As we know from first-hand, long-distance experience, you can push the 1500 EcoDiesel to 38 mpg. CR found in its own testing that the truck had, "about the same fuel-economy numbers that we typically see in a midsized SUV," said Jake Fisher, CR's director of automotive testing, in a statement. Speaking of midsized SUVs, CR also announced this week that the new Toyota Highlander Hybrid got the top spot in CR's ratings in that category. CR liked pretty much everything about the SUV, saying that the "transitions between electric power and the gas engine are seamless" and that, "the new Highlander also handles better, with a steadier ride and reduced body lean in corners." You can find more at the CR website, in the October print issue of Consumer Reports or in the video and press release below. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. RAM ECODIESEL 1500 TOPS CONSUMER REPORTS FULL-SIZE PICKUP TRUCK RATINGS Redesigned Toyota Highlander Hybrid Climbs to Top of Midsized SUV List Yonkers, N.Y.- The Ram 1500 EcoDiesel climbed to the top of Consumer Reports' full-size pickup truck ratings with an impressive performance in the organization's fuel economy tests. The EcoDiesel (82 point overall road test score) turned in a best-in-class fuel economy of 20 mpg overall and 27 mpg on the highway, to help it score better than the previously tested Ram 1500 V8 (81) regular gas version and Chevrolet Silverado 1500 LT (80).