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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 gets TRD treatment in UK

As dearly as we love the Toyota GT86 / Scion FR-S / Subaru BRZ franchise, we readily admit we wouldn't look sideways at a model with a bit more firepower. And while that's not quite on the table yet, Toyota has been busy amping up the visual firepower of its rear-drive coupe with a whole host of TRD parts. To this point, that's been a largely à la carte affair, but the automaker's UK outpost has just announced a special-edition model that allows our British friends to pick up the whole shooting match all in one go.
The Toyota GT86 TRD will only be available in black and white, and just 250 examples are to be built. As you can see from the excellent gallery above, the catalog of look-faster bits include a more aggressive front air dam, side skirts, rear bumper fascia, spoiler and unique 18-inch forged alloys. Additional flourishes include a TRD shift lever and branded radiator cap. The sole concession to actual performance? A "fast-response quad exhaust" that might only improve things audibly - 0-62 mph is apparently unchanged at 7.7 seconds, and the top end is still 140 mph for the manual transmission model. (The auto gets by with 8.4 seconds and 130 mph).
Pricing? Glad you asked. £31,495 for GT 86 TRD manual, £32,995 for the automatic - that's nearly $50,000 US for the tripedalist and just over for the automatic. (Those are heady prices, but bear in mind that UK MSRPs and taxes are generally significantly higher than their US counterparts). If the standard GT86 is more your speed, it still rings up at a more affordable £24,995 - roughly $39,500 - leaving plenty of budget for actual performance parts. No word yet on North American availability of a special TRD model, but we've got a call in...

Toyota Expands Airbag Recall To 2.2 Million Vehicles Worldwide

Was your Toyota inspected under the company's recall campaign for faulty airbag inflators last year? You might have another trip ahead to have it repaired again. The automotive giant says that it found "the involved serial numbers provided by the supplier were incomplete, and did not include all of the potentially involved inflators," according to its official announcement. That means more replacements are needed. Toyota's April 2013 inflator recall covered the Corolla, Matrix and Tundra from the 2003 and 2004 model years, the Sequoia from 2002 to 2004 and the Lexus SC 430 from 2002 to 2004. At the time, the company said it would need to inspect about 510,000 vehicles in the US but only expected to replace around 170,000 inflators. However, the latest announcement increases that figure to about 766,300 vehicles in the US. Toyota spokesperson Cindy Knight told Autoblog that the new amount is the combination of owners who need to have their vehicle looked at again and those who didn't come in for the initial recall. The company learned about the problem when Takata, the supplier, provided it with an improved list of the faulty part's serial numbers. According to The Detroit Free Press, the latest recall affects about 2.27 million vehicles from them worldwide. Knight said owners would receive notification of the problem around the end of the month but repairs would come in phases because the automaker doesn't have all of the necessary parts at the moment. The original problem occurred because the front passenger airbag inflator from Takata could have an improper propellant that could cause it to burst in an accident and not allow the airbag to deploy properly. Toyota inspected all the vehicles listed but only changed the inflators with specific serial numbers. Now, it's replacing them all. This wasn't just a problem for Toyota, though. Honda, Nissan and Mazda also used the faulty inflators and issued recalls at the same time. Autoblog has contacted the other Japanese automakers about whether similar campaigns are necessary for them. We will update this story, if we hear back from them. Scroll down to read Toyota's announcement. UPDATE: Honda spokesperson Jessica Howell sent along the following statement: Honda is aware that Toyota recently announced a recall of front passenger's airbag inflators. Honda is not aware of any incidents in our vehicles related to Toyota's action. We are currently investigating the potential implications to Honda vehicles.