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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."

Next-gen Toyota Tacoma to debut at Detroit Auto Show

Toyota's confirmation comes on the heels of General Motors' successful launch of its own midsize pickups. The next generation of the Toyota Tacoma pickup truck will be revealed in January at the Detroit Auto Show, a top executive confirmed Thursday. Bob Carter, senior vice president of automotive operations for Toyota, offered no other details, but the new version of the pickup is expected to have significant upgrades compared with the aging model on sale now. Our spy shooters caught a prototype testing this summer, and rumors of the new generation have been swirling for months. We've also previously reported that Toyota is planning to ramp up production next April at a factory in Mexico that builds the Tacoma. Toyota's confirmation comes on the heels of General Motors' successful launch of its own midsize pickups, the Chevrolet Colorado and GMC Canyon, which have garnered awards, positive reviews and solid sales since they arrived in showrooms this fall. It's unclear how large the new Tacoma will be, especially considering that the Canyon and Colorado flirt with fullsize territory. The Tacoma was last updated in 2012, and the segment has changed dramatically since then with the addition of the GM trucks. Another Tacoma competitor, Honda's aging Ridgeline, is also expected to re-launch in 2015, which would leave the Nissan Frontier as the oldest truck in the field. Tacoma sales have slipped 4.1 percent to 140,757 units this year, though they posted a 3.3-percent gain in November. Meanwhile, Carter also said Lexus will reveal two performance vehicles, though he didn't elaborate. "I'll leave it at that, but I promise you'll enjoy it," he said coyly. Lexus just showed the LF-C2 convertible concept at the Los Angeles Auto Show.

Suzuki and Daihatsu join Toyota electric vehicle venture

TOKYO — Suzuki Motor Corp and Daihatsu are joining a commercial electric vehicle coalition led by Toyota Motor Corp, the carmakers announced on Wednesday, helping the Japanese alliance expand its focus from trucks to smaller cars. The two automakers will each acquire a 10% stake in the joint venture, on par with Isuzu Motors and Hino Motors, while Toyota will hold a 60% stake, they said. "With Suzuki and Daihatsu joining the project and working together, we'll be able to expand our circle of cooperation to not only cover commercial vehicles but also mini vehicles," said Toyota President Akio Toyoda. "With this expansion, I believe that we'll be able to take one step closer to a better mobility society," Toyoda said. The move comes as Japanese automakers face growing competition from tech giants and other rivals making electric and driverless cars. Toyota, Isuzu and Hino launched the Commercial Japan Partnership Technologies Corporation in April to bolster their competitive edge in connected, commercial vehicles. Daihatsu's president Soichiro Okudaira said joining the pact and introducing connected, mini-commercial vehicles would allow data sharing, a major benefit for companies to provide better services to customers and improve logistics efficiency. (Reporting by Eimi Yamamitsu; Writing by Ritsuko Ando; Editing by Louise Heavens) Related Video: Green Suzuki Toyota Daihatsu Electric Akio Toyoda