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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."

GM repairing 40,500 Pontiac Vibes as part of Toyota airbag recall

General Motors has confirmed to Autoblog that the Pontiac Vibe is included in Toyota's just-announced recall action. The Vibe and the Toyota Matrix share a large number of parts, including the affected cable to the airbag.
"About 40,500 Pontiac Vibes from the 2009-2010 model years are included in the Toyota recall. Toyota designed and engineered the Vibe for Pontiac. GM will service customers with these vehicles when Toyota makes the parts available," said GM recall spokesperson Alan Adler to Autoblog in an email.
The recall covers 1.3 million Toyota units in the US, including 2009-2010 Corolla, Matrix and Tacoma, the 2008-2010 Highlander, the 2006-2008 Rav4 and 2006-2010 Yaris, plus the addition of the 2009-2010 Vibe. The models all have their airbag module attached via a spiral electrical cable. The connections on this cable can be damaged when turning the steering wheel. Once broken, the airbag deactivates and the airbag warning light comes on. Toyota has an improved part, but it's still making preparations to begin repairs. It will begin notifying owners soon.

Toyota says president, chairman of scandal-hit Daihatsu unit to step down

TOKYO — Toyota Motor Corp said on Tuesday both the president and chairman of Daihatsu Motor will step down almost a year after the small-car unit said it had rigged collision safety-tests. The departures are among the most drastic changes Daihatsu has made so far, as Toyota seeks to return the brand to its roots as one of Japan's most iconic compact car makers. Toyota faces a potential hit to its reputation from the safety certification lapses at Daihatsu, as well as separate governance issues at truck maker Hino Motors and affiliate Toyota Industries. The scandals at the three companies triggered a rare apology of Toyota Chairman Akio Toyoda last month. In a statement, the world's top-selling automaker said its chief executive officer for the Latin America and Caribbean region, Masahiro Inoue, will replace Soichiro Okudaira as Daihatsu's president effective March 1. Daihatsu's chairman, Sunao Matsubayashi, will also step down and will not be replaced, Toyota added. The outgoing Okudaira had worked at Toyota for nearly four decades before becoming president of Daihatsu in 2017, a year after it became a wholly owned Toyota subsidiary. Toyota Chief Executive Koji Sato told reporters, however, that the organizational change at Daihatsu was not carried out as a punishment for the outgoing executives. In volume terms, Daihatsu accounted for 7% of Toyota's total group sales of 11.2 million vehicles in 2023, including those of the luxury Lexus brand and Hino Motors. Given the misconduct over the safety test certification applications, Daihatsu also will be removed from a commercial vehicle partnership known as the Commercial Japan Partnership Technologies (CJPT), the automaker said in a separate statement. The partnership was established in April 2021 by Toyota, Hino and Isuzu Motors to facilitate technology development for commercial vehicles. Suzuki Motor and Daihatsu joined in July the same year. Daihatsu's 10% equity stake in the partnership will be transferred to Toyota, the statement said. (Reporting by Daniel Leussink and Satoshi Sugiyama; Editing by Kim Coghill & Shri Navaratnam and Miral Fahmy) Government/Legal Hirings/Firings/Layoffs Plants/Manufacturing Toyota Daihatsu