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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 launches new Passo hatchback in Japan [w/video]

With considerable manufacturing capacity here in the United States and even a NASCAR program, it'd be all too easy to categorize Toyota as an American automaker. Only it's not. It's Japanese, of course. And back in the Japanese Domestic Market, it offers a whole range of models we'll never see in North America. Models like the Crown sedan, Noah minivan and this, the new Passo hatchback.
Sold in various markets as the Daihatsu Boon, Daihatsu Sirion, Perodua Myvi and (for a time) the Subaru Justy, the Toyota Passo is a compact hatchback that slots in size-wise between the Yaris sold in America and the Aygo offered in Europe (except the Passo is taller than either).
Power comes from a 1.0-liter engine with 69 horsepower that can be had in front- or all-wheel drive, or a 1.3 driving 95 horses to the front wheels alone. A continuously variable transmission is on duty regardless of engine choice. Front-drive models get a stop/start system, but even all-wheel-drive versions are eligible for government tax credits. That's because, though the new Passo only appears to be mildly updated, the engines have been thoroughly reworked to deliver 30-percent better fuel economy than the previous model, coming in 20-percent better than the standards being enacted by the Japanese government for next year.

Toyota recalls 370k Sienna minivans, 10.5k Lexus GS models over separate issues

The year of the recall continues, but this time it isn't from General Motors. Toyota is announcing two, separate recalls affecting a pair of its models.
First, Toyota is recalling 370,000 Sienna minivans from the 2004 to 2011 model years that are registered or originally sold in cold-weather states. The problem is that the spare tire carrier assembly cable can be splashed by water contaminated with road salt and cause corrosion. There is a splashguard in place to prevent this, but it sometimes gets lost in "normal usage," according to the company. If the cable does break, then "the spare tire may separate from the vehicle."
This is actually the second repair for this problem for some of these vehicles. In 2010, Toyota issued a recall on 600,000 Siennas from the 1998 to 2010 model years. At the time, it installed a new splashguard and sprayed the area with an anti-rust chemical. However, according to Toyota spokesperson John Hanson speaking to Autoblog, the campaign worked for the 1998 to 2003 models but wasn't sufficient for the newer ones. For the latest recall, the vehicles are getting the entire cable replaced with a stainless steel unit and a new splashguard.