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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."

Cosworth announces Power Packages for Subaru BRZ, Scion FR-S with up to 380 hp [w/video]

Cosworth stands on the list of the most famous engine tuners in the world with its DFV engine engine dominating Formula One for a time in the '70s. So when it teases plans to take on the FA20 engine from Subaru and Toyota found in the BRZ, Scion FR-S and Toyota GT86 abroad, our interest is indeed piqued. Cosworth is promising to take the 2.0-liter, four-cylinder boxer engine from its current 200 horsepower all the way to 325 hp and even 380 hp in a future track version through a series of staged Power Packages. At the moment, only the first stage is available that takes the mill to a potent 230 hp.
Cosworth says that its new strategy is to offer its upgrades in kits rather than individually so that it can be sure that everything works and fits when owners receive it. The Stage 1 Power Package emphasizes helping the FA20 breathe better and includes a nearly complete replacement for the stock exhaust system. There is a sports exhaust with four-inch, diagonally cut, polished tips and Y-shaped muffler, an overpipe front pipe with a spherical resonator and a new manifold header that is 22 percent lighter the standard unit. In addition to that, the kit comes with a software reflash, low temperature thermostat, Cosworth badge and plaque.
The stage one kit is available now, and stages two and three go on sale later this summer, according to its website. Autoblog contacted Cosworth for pricing information for the kits. We will update this story, if we hear back. The company also released a video showing off the exhaust upgrades. Scroll down to watch it and read the full release, below.

Mini Minor to be co-developed with Toyota

It was back in 2011 when Mini first showcased the prospect of an even smaller hatchback with the Rocketman concept at the Geneva Motor Show. In the nearly four years since, parent company BMW has hemmed and hawed on the possibility of putting it into production, but the latest word from Europe has it that the project is a go. According to Automobile magazine, Mini is realigning its product portfolio into five pillars: the essential hardtop we've already seen (available in two/three- and four/five-doors), the convertible, the upcoming new Clubman wagon (coming this summer with full-size auxiliary suicide doors on both sides), the next-gen Countryman crossover in 2016 and two new model lines. One will be the production version of the Superleggera roadster concept, earmarked for 2018. The other will be the Minor, a smaller city car reviving a long-gone model name and presaged by the aforementioned Rocketman concept. But for that last one, Mini won't go it alone. To develop the mini Mini, BMW will reportedly turn to its partnership with Toyota. The relationship is already set to yield a new Supra and Z4 and share fuel cell and other technologies. But this would broaden the partnership to include a small hatchback. However rather than use the existing (or next-gen) Aygo, which is already built under joint venture with PSA Peugeot Citroen (with which BMW previously had a joint engine venture), word has it that the BMW and Toyota will develop a new platform for the project – one that will be used by both partners. The new product plan doesn't leave much room for the Mini Coupe and Roadster (which have already been discontinued), for the Paceman three-door crossover (which will suffer the same fate) or for the projected seven-seater minivan. But the addition of the new Superleggera roadster and super-mini Mini aren't likely to leave us wanting for either. Related Video: