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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, Scion FR-S sales disappointing worldwide?

Okay, folks - it appears we've got a problem. The Toyota GT86, Europe's counterpart to our own beloved Subaru BRZ and Scion FR-S coupes, is apparently not selling too well. This, according to Toyota's European Vice President of Research and Development, Gerald Killman, is what's limiting plans for additional variants of the rear-drive coupe.
"A faster version of that car would be at the top of most people's wish lists, but like the cabriolet, it is hard to justify a business case to push either model into production based on the current sales," Killman told AutoExpress. "Personally, I think that engine could use a little bit more," he added.
More troubling is that slow sales aren't limited to the Euro-spec car, with Killman claiming that the GT86 have been missing sales targets in major markets around the globe. It may not be that the US is one of those major markets, though. Scion's Vice President, Doug Murtha, tells Autoblog that his brand is happy with the sales of its version of the GT86, the FR-S. 18,000 units were sold last year, which Murtha says is "generally in line with original expectations for the car."

Toyota mulling more Tundra, Tacoma capacity in TX

Toyota may be expanding its pickup truck production at its San Antonio, TX factory following calls from dealers for more Tacoma and Tundra models, according to a new report from Automotive News.
The San Antonio plant is currently able to produce 250,000 trucks on two shifts with overtime, while a secondary facility in Tijuana, Mexico can build an extra 50,000 Tacomas. Despite this capacity, and the fact that Tundra is a slow seller relative to the full-size trucks from Ford, Ram and Chevrolet/GMC (not to mention the Tacoma being part of a segment with diminishing sales), Toyota franchisees apparently can't get enough of the trucks.
"Dealers are telling us they could sell more Tacomas and Tundras," said Bill Fay, the general manager of the Toyota Division. "We are evaluating our footprint and capacity." According to AN, Toyota has moved over 248,000 trucks through November.