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Honda, Subaru airlifting parts to bypass port labor diputes

It should be abundantly obvious that a vital element in building cars is actually having the components on hand to assemble them. A labor dispute on the West Coast between the International Longshore and Warehouse Union and management is not making that quite so easy for some Japanese automakers. Work slowdowns at the ports have pushed Honda and Subaru parent Fuji Heavy Industries into flying some parts into the country. The two automakers began shipping by airplane late last month to avoid production delays, according to Bloomberg, but it has been an expensive solution. Subaru's chief financial officer said the decision cost around $60 million more per month than sending components by cargo ship. They aren't the only companies dealing with the problem, either. Toyota reportedly stopped overtime assembly at some of its factories here because of the delays in getting parts, according to Bloomberg. The dockworkers have been negotiating on a new contract since May 2014, and the current offer on the table to them has offered a 3 percent raise, according to Bloomberg. Although, the union is reportedly considering another slowdown at 29 ports along the West Coast in the coming days. News Source: BloombergImage Credit: Nick Ut / AP Photo Auto News UAW/Unions Honda Subaru Toyota shipping port labor dispute

Andrew Gilleland is new VP of Scion, Murtha moves to Toyota

Scion is getting some fresh blood at the top as Andrew Gilleland (pictured above) becomes the new vice president to take over for Doug Murtha. Gilleland is no stranger to the division, and served as the national field operations manager early in the brand's launch. Murtha moves to take leadership of corporate strategy and planning for Toyota in North America. "Now it's Andrew's charge to spread the message of the style and value of the iM and iA, as well as a third new vehicle that will be added to the lineup," Toyota division group vice president Bill Fay said in the announcement. Gilleland moves up from being general manager of Toyota's central Atlantic regional office. He takes the reins at Scion at a potential turning point for the division. Sales volume for the year through August is down 22.1 percent to 32,691 vehicles, but some big changes are afoot. The long-lived xB is likely about to bow out, and the brand is launching two new products with the iM and iA. They're getting some celebrity advertising, too. Spy shots also suggest the FR-S might get a refresh soon. Plus, the third model Fay teases is expected to be a compact crossover, possibly with styling inspiration from the Toyota C-HR concept. Scion could get a big boost by having an entry in that booming segment. New Products, Previous Player - Scion Introduces New Vice President Andrew Gilleland Returns to Youth Brand September 24, 2015 TORRANCE, Calif. (Sept. 24, 2015) – In the early days of Scion, when xAs and xBs were flying out of dealers' showrooms, Andrew Gilleland was the National Field Operations Manager for the youth brand. He was responsible for working with dealers to ensure they embraced the new products and processes Scion offered. Now, Scion is entering its teen years, and Gilleland is back as Vice President of Scion, once again encouraging dealers to sell its new models and investigate new methods to attract young buyers. "Scion has sold nearly a million vehicles since I left in 2005 and I'm excited to be back leading this team," said Gilleland. "The iM 5-door hatchback and iA sports sedan arrived at dealerships earlier this month and the response has been great.

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."