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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 GT86 engineer Tada recounts how sports car came to be

Because the Toyota GT86, Scion FR-S and Subaru BRZ coupes are now a reality, it's almost hard to imagine the struggle that had to happen within the large, conservative corporate structures at both automakers for the joint project to even get off of the ground.
Speaking to those struggles on Toyota UK's Toyota Blog, GT86 Chief Engineer Tetsuya Tada enlightens us with a recap of the sports car's earliest origins. For Tada, the first stages of the project must have seemed almost as dreamlike as the final product is to drive.
Said the Chief, "I had been working in the minivan department engineering new product, but a month after the meeting I was summoned. 'Forget about minivans,' they said, 'you are now working on the sports-car project.'"

Toyota GT86 convertible could debut in March

The dates are lining up, now we wait to see how the badges align. Just before the Toyota GT 86/Scion FR-S/Subaru BRZ line-up was introduced at the Tokyo Motor Show last year, there was a report that Subaru was considering a convertible while Toyota wouldn't even comment on it. That got swapped around when earlier this year the chief engineer on Toyota's side said a convertible was coming, and then a Scion FR-S droptop was confirmed for early 2014.
Autocar now reports that the Toyota GT 86 convertible will make its first appearance at the 2013 Geneva Motor Show in March. In a car whose specs like weight, packaging, horsepower and center of gravity were all tightly controlled to get the most from the least, the changes necessitated by chopping the roof could make this a very different car. It's said to employ a fabric roof to keep a "small" weight gain check, and the suspension will be softened to work more harmoniously with the decreased body stiffness. And somewhere in all that the back seat and trunk space will need to take a hit.
In other news, Autocar says the hi-po GT 86 with some kind of capacitor system instead of batteries is being worked on for 2015.