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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 86 most likely to get more power through more displacement? [w/poll]

The Sydney Morning Herald has spoken to Tetsuya Tada, chief engineer of the Toyota 86 (our version of it, the Scion FR-S, is pictured above), and they've been promised that more power is on the way. We've heard a lot of speculation about a more powerful Toyobaru since before the standard model was even launched. The only question now is how the power will be delivered, and among the engine concepts we've already heard about - turbo, supercharger, twin-charged, hybrid - is a new one: more displacement.
Tada said that an engine with more displacement than the current coupe's 2.0 liters is being tested alongside a turbocharged and a hybrid-assisted motor. The SMH cites "inside sources" as saying the displacement option is the one likely to get the go-ahead, and suggests increased bore and stroke will see the engine grow to 2.5 liters, horsepower to about 250 - a 50-hp increase over the present car.
While that's apparently the betting man's solution for the long-awaited increase in gumption, what happens with the next generation could be more wide open than we suspected. According to the report, Tada "hinted that [a successor] could be a radically different car, potentially dropping the boxer engine altogether." He said once they've sorted out the concept for the second generation car, then they'll sort out an engine. That's where a turbo option could come to market, perhaps the turbocharged four-cylinder Toyota is developing for the Lexus NX crossover or a hybrid system that uses a capacitor.

How Charlotte lost to Plano without even knowing it was dealing with Toyota

With Toyota set to relocate its North American headquarters to the Dallas, TX suburb of Plano following a top-secret, 100-city search, the cities that missed out can now begin asking themselves what happened during a process they apparently knew little about.
That's a particularly brutal task for Charlotte, which, according to North Carolina's Secretary of Commerce, Sharon Decker, finished second to Plano. While Toyota has been fairly open about what it was looking for in a new headquarters city - direct flights to Japan, proximity to its US production facilities, a lower cost of living, high-quality educational facilities and finding a neutral site suitable to the California, Kentucky and New York-based employees that would be relocated - it's been less open about how the finalist cities, which also included Atlanta and Denver, stacked up against each other.
The Charlotte Observer has a few ideas. Part of the problem is the distinct lack of direct flights between Charlotte and Asia. US Airways, which operates a hub at Charlotte/Douglas International Airport, doesn't fly to Asia.