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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 Recalling 1.67 Million Vehicles Worldwide

UPDATE: Toyota is now announcing specifically which models are covered under its fuel pipe recall in the US. The company is repairing about 423,000 Lexus models that include the 2007-2010 LS, 2006-2011 GS, 2006-2011 IS, 2010 IS C and 2008-2010 IS-F. The automaker says that it isn't aware of any fires, crashes, injuries or fatalities caused by this problem. According to Toyota, the recall is because it's possible for the fuel delivery pipes and the fuel pressure sensor to form a bad seal with the gasket between them because of a protective coating protecting against corrosion on the pipes. It's possible for this to eventually cause a fuel leak, and obviously in a hot engine bay that's a potential fire risk. To fix the problem, dealers will replace the gasket and repair the gasket seating surface between the fuel delivery pipe and the fuel pressure sensor. The company will begin notifying owners soon. You can find the official press release, below. Toyota is issuing three separate recalls covering 1.67 million vehicles worldwide with most of those models in Japan. It looks like the campaigns' impact on the US may be smaller, though. According to Reuters, Toyota isn't aware of any accidents, injuries or fatalities affecting the models. Some yet-unnamed Lexus models might also be affected. The largest of the campaigns does not currently affect any US-market vehicles. About 802,000 units of the Toyota Crown Majesta, Crown, Noah and Voxy in Japan are being repaired to replace a seal that could leak in the brake master cylinder. Those already leaking get a new brake booster, as well, according to Reuters. The only recall currently believed to affect the US is due to a problem covering approximately 759,000 vehicles with 423,000 of them here. The repair is to fix a faulty fuel delivery pipe that could cause a fire if the fuel leaks out. Unfortunately, we don't know which models it covers. Autoblog spoke to Toyota spokesperson Mona Richard and was told the information was still "under embargo." When exactly that embargo will lift isn't yet known, but we're on the case. Finally, Toyota is recalling 190,000 Corolla Rumion and Auris models in Japan for a faulty evaporative emission control unit. Autoblog is in contact with Toyota, and we'll update this story as soon as we know more about its affect on the US market.

Toyota, Daihatsu and Suzuki team up to unbox some fun-size electric kei vans

The G7 Summit is happening in Hiroshima, Japan, right now and some automakers have taken the opportunity to announce new projects. Toyota, their wholly owned subsidiary Daihatsu, and Suzuki (of which Toyota owns about 5%) made news with a trio of electric micro-vans built to kei car specifications. The battery-electric vans are part of an industry-wide push toward carbon neutrality. Kei-class vehicles, in addition to limited displacement gasoline engines, have strict dimensional restrictions that allow them to navigate the often narrow streets in dense urban areas. They're also privilege to certain tax breaks and parking benefits.  [gallery ids="2474953,2474954"] The engine size rules obviously don't apply to the electric vans, but they will still conform to the size boundaries. Kei vans are often used to solve the "last mile" problem in logistics since they're able to whiz around crowded streets inaccessible by larger commercial vehicles.  Daihatsu, which specializes in kei cars, will build the vans and name their variant the HiJet Cargo. The HiJet name has been a consistent one in the company's lineup since 1960, but these new versions will be front-wheel-drive in contrast to the rear-wheel-drive gasoline variants. Toyota's version will be called the Pixis Van, while Suzuki will be named the Every, a nameplate that's been around since 1982. Aside from the badges the vans appear identical. Range is said to be approximately 200km (124 miles) on a single charge.  The exhibition was held in conjunction with the Japan Automobile Manufacturers Association, which former Toyota CEO Akio Toyoda heads. Toyoda stepped down from the top position at the company his grandfather founded in April, but still takes a overseer role as Chairman. Toyoda was criticized for being slow to adopt EVs, and new CEO Koji Sato has emphasized the role of battery-electrics moving forward while still taking a multi-front approach to carbon neutrality with hydrogen and hybrids. These vans were likely in development before Toyoda's retirement, though.