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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."

Watch Congress sample Toyota's i-Road 3-wheeler concept

Toyota brought its new i-Road, a three-wheeled, all-electric low-speed vehicle that debuted in 2013 at the Geneva Motor Show, to the Capitol for some of our elected officials to test out. As easy as it is to forget that politicians are people, too, it was refreshing to see a human side to many of them as they zipped about one of the Capitol's many meeting rooms.
We'd say their reactions were surprisingly positive. Of course, some were just down there because Toyota is a big presence in their respective districts, but the bulk of the senators and representatives seemed like they just wanted to zip about the makeshift indoor course on the leaning trike.
Take a look below at the video from Bloomberg.

Toyota unveils two new small displacement engines

Toyota introduced a pair of brand-new engines in Japan today, that it says will eventually spawn 14 different variants by 2015. Where these two engines stand out in today's world, is that neither mill boasts direct injection, and both are naturally aspirated.
The larger of the two is a 1.3-liter, while the smaller engine, a 1.0-liter, was developed in collaboration with Daihatsu. What makes these two unique is that they both use the Atkinson cycle. Now, we aren't going to bore you by explaining just what this is - there's Google for that. Suffice it to say, Atkinson engines are highly efficient, but that efficiency comes by sacrificing power. That's why they're so popular in hybrids, which can offset the power losses.
This focus on fuel efficiency extends throughout the new engines, which also benefit from tweaks like a cooled exhaust gas recirculation system and a trick intake port, while the 1.3 employs Toyota's iE variant of variable valve timing. Both engines can be fitted with stop-start tech. According to Toyota, when fitted with stop-start the 1.3 should provide around a 15-percent bump while the 1.0-liter will increase economy around 30 percent, when they arrive on the road.

Watch this cement truck roll into Toyota minivan from driver's point of view

If you've been having an easy day and haven't received your daily dose of unmitigated terror, then this video is for you. Dr. Guan Zhu, a Texas A&M professor, caught the above view on his dashcam in College Station, TX, as a cement truck ran a red light, lost control and rolled into his Toyota Sienna minivan.
Although he received only minor injuries, Dr. Zhu says that he blacked out during the accident. The truck driver also avoided serious injuries, and the Sienna took the hit rather well too. Scroll down to watch the footage and report from KBTX. Hopefully, this is as close anyone else ever gets to a terrifying event of this nature.

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 issues multiple recalls for 6.4 million vehicles worldwide

It looks like 2014 may go down as the year of recalls. We were already at a record pace, and now it seems Toyota is recalling 6.39 million vehicles worldwide, including about 30 of its models for a variety of problems. None of the faults have caused any injuries or fatalities, but there have been two reports of fires caused by a defective engine starter motor.
Toyota's numbers show 1.772 million vehicles being recalled in the US, but that includes some overlap because the Yaris is being repaired for multiple faults. According to The Detroit News, there are 2.36 million affected models in all of north North America, 1.09 million in Japan and 810,000 in Europe, plus smaller numbers in other regions.
Among the vehicles recalled in the US are 1.3 million units of the 2009-2010 Corolla, Matrix and Tacoma, the 2008-2010 Highlander, the 2006-2008 Rav4 and 2006-2010 Yaris. The problem is that the driver's airbag module is attached via a spiral electrical cable. The connections on the cable can be damaged when the steering wheel is turned, which deactivates the airbag and causes the airbag warning light to come on. Toyota is replacing the cable with an improved part, but it's still making preparations to begin the repair. The company is sending affected owners notifications in the mail. According to The Detroit News, an unspecified number of Pontiac Vibe vehicles are also included in this recall because it shares the part with the Matrix.

Total auto recalls already on record pace in 2014

If you've noticed that there have been more recalls than usual this year, you may be on to something. According to a report from the National Highway Traffic Safety Administration, the US market is on pace to break a record for recalls. In 2013, 22 million cars were recalled. We're only a third of the way through 2014, though, and we've already halved that figure, with 11 million units recalled. That's wild.
Considering the past few months, it shouldn't be a surprise that General Motors is leading the charge, with six million of the 11 million units recalled coming from one of the General's four brands. Between truck recalls, CUV recalls and the ignition switch recall, 2014 hasn't been a great year for GM.
Other recall leaders include Nissan (one million Sentra and Altima sedans), Honda (900,000 Odyssey minivans), Toyota (over one million units in a few recalls), Volkswagen (150,000 Passat sedans), Chrysler (644,000 Dodge Durango and Jeep Grand Cherokee SUVs) and most recently, Ford (434,000 units, the bulk of which were early Ford Escape CUVs). So while it's been a bad year for GM so far, its competitors aren't doing too well, either.

Jay Leno gets behind the curtain on the design of the Toyota FT-1 concept

Hinting at the future of Toyota performance vehicles, the FT-1 concept was one of the stars of the Detroit Auto Show this year. It even nabbed fourth place in our Editors' Choice list. While he's a few months behind the car's official reveal, Jay Leno managed to get the only existing concept of the sports coupe wheeled into his garage to take a closer look, and he's pretty impressed.
Leno speaks with Alex Shen and William Chergosky, the exterior and interior chief designers of the FT-1 respectively, to get a better idea of the inspirations behind the concept. Jay heaps high praise on it for mixing Italian and Japanese design and says he likes the look even more than the Lexus LFA. The coupe isn't a product of either country, though. It was penned at Toyota's CALTY Design Research center in Newport Beach, CA.
The designers go into the entire history of the FT-1, and Shen even admits that Toyota design lacks an emotional factor at the moment. It's a fascinating interview behind some of the little touches you might miss at first glance. Unfortunately, the model doesn't have the green light for production yet and may never get made. In any case, scroll down to watch Leno swoon over the coupe.

Vote to unionize Toyota Canada plant faces delay

Volkswagen isn't the only automaker with high-profile unionization efforts afoot at one of its North American factories. Unifor, Canada's largest private-sector union, is attempting to organize Toyota's factories in Ontario, reports Reuters. A vote was originally set for next week, but Unifor has apparently found more workers eligible to vote, delaying the proceedings. It hasn't rescheduled the ballot yet, but claims there are 7,500 employees with the right to vote, with over 3,000 having already signed union cards.
Toyota is pushing against organizing, saying that workers already have a payment and benefits near the top of the industry, and noting that it has never laid off a permanent employee in Canada. Unifor has reportedly countered by saying that about a quarter of the workforce is operating under a temporary contract, which receives lower benefits.
The automaker has three factories in Ontario - two in Cambridge and one in Woodstock. To form a union, a majority of eligible employees must vote to join Unifor. If successful, they would be the first wholly owned Toyota plants in North America to be organized. Previous attempts to unionize the Japanese automaker's Canadian factories in 2001 and 2008 failed due to lack of support.

Toyota NA CEO says his excitement for hydrogen sedan is rising

Toyota has an undeniable vested interest in seeing its hydrogen sedan succeed when it goes on sale in the US next year, so it's no surprise that the company's North American CEO, Jim Lentz, says that he's got more hope for the car now than ever before. And if we remember ways that others in the company, like Bob Carter, have loudly sung hydrogen's praises, we have to assume that positivity is running awful high in Torrance. In fact, Lentz said that the US side of the company is far more excited by the H2 car than colleagues in Japan. Speaking at The Wall Street Journal's ECO:nomics conference in Santa Barbara, CA this week, Lentz said: After we've seen the product, understand its range, its driving dynamics, its refueling, we're a lot more bullish than Japan - probably about fivefold more bullish. It's just a question of how many can be produced now. Well, we've driven this car, and we still feel that Toyota is placing a big bet on the technology. One important issue is cost, but Lentz would not say exactly how much the car costs to make or what it will be priced at. He did say, though, that the production cost has dropped by 95 percent from the $1 million price tag the car wore ten years ago. That hints at a production cost of around $50,000. Lentz also said he thinks it will take at least a decade for hydrogen vehicles to hit sales of 500,000 per year in the US. Speaking to Bloomberg, he said: Their acceptance could get off to a quicker start than the hybrids did. I think you're going to see a lot more marketing of the concept of fuel cell much sooner than you did for hybrids, because basically the whole industry is behind it.