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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."

Recharge Wrap-up: Mazda, Subaru and Toyota PHEV, Nomadic Power grant

The next generation of the Toyota Prius Plug-in Hybrid looks to be important for Mazda and Subaru as well. Toyota will likely need to sell more of the new plug-in hybrid to meet stricter ZEV standards in California. That means it will get more extra electric range, as customers have been asking for. Subaru and Mazda will also have to adhere to the California standards beginning in 2018. Those two smaller automakers will likely license a plug-in hybrid powertrain from Toyota in order to fulfill compliance. Read more at Green Car Reports. Tesla is partnering with Dalhousie University to improve battery technology. Tesla signed a five-year research agreement with Dalhousie's Jeff Dahn, a lithium-ion battery researcher. Dahn and the 25 researchers in his lab will work with Tesla's Director of Battery Technology, Kurt Kelty, to increase capacity through improved materials. The collaboration could be important both for Tesla's automotive and stationary batteries. "Our research group's goal is to increase the energy density and lifetime of Li-ion batteries, so we can drive down costs in automotive and grid energy storage applications," says Dahn. Read more from Dalhousie University. Nomadic Power is receiving a European Commission grant worth ˆ2 million (about $2.26 million) for trailer-mounted mobile batteries. Nomadic Power's mobile batteries, called Nomads, have incorporated photovoltaic systems and can be used to extend the electric driving range of a plug-in vehicle, or to provide backup power to a home. The Nomads use an intelligent energy management system to learn and predict user behavior and manage the solar system based on weather forecasts. "We see a strong future in electric-powered mobility and an increasing use of renewable energy, photovoltaic power in particular," says Nomadic Power CEO Dr. Manfred Baumgaertner. "Our mobile batteries have great potential in these markets that recently got a significant shot in the arm by Tesla's announcements." Read more from Nomadic Power, and at Green Car Congress. Related Gallery 2012 Toyota Prius Plug-In: First Drive View 24 Photos News Source: Green Car Reports, Dalhousie University, Green Car Congress, Nomadic PowerImage Credit: Nomadic Power Government/Legal Green Mazda Subaru Tesla Toyota Technology Electric recharge wrapup

Toyota may return to F1 under Lexus banner

A new report in from the website Club Lexus claims to have insider knowledge about a return to Formula One racing by Toyota, this time under the auspices of the Lexus brand. Toyota competed in F1 from 2002 through the 2009 season. That final year saw the team return competitive, if inconsistent results, but the larger economic woes in the automotive market made a decision to pull the plug relatively easy at the time.
Now, citing recent interviews with Toyota executives and insider sources, Club Lexus says that the move to re-enter F1 for the 2014 season is "all but finalized." The choice to go with the Lexus nameplate over Toyota makes some sense, too, considering the success that rival Infiniti has had in recent years through its partnership with Red Bull Racing. Further, the emerging Lexus identity as a performance car builder, with a strong background in hybrid vehicles, could help the F1 move resonate with buyers.
A few technological factors and formula changes within F1 offer some credence to the Lexus rumor, too. F1 will increase the available capacity of KERS from 60kW to 120kW, a change that theoretically benefits the hybrid-savvy Toyota. What's more, 2014 will see a switch from the current 2.4-liter V8 engines to 1.6-liter turbocharged V6s. A Lexus team that goes racing in 2014 will be on a level playing field with the rest of the grid then, with all teams adjusting to and continuing to develop the new engines.