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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."

Porsche 911 Carrera 4, Alfa Romeo Giulia Quadrifoglio and a chat with Jean Jennings | Autoblog Podcast #626

In this week's Autoblog Podcast, Editor-in-Chief Greg Migliore is joined by Road Test Editor Zac Palmer, Associate Editor Byron Hurd and special guest Jean Jennings. The gang kicks off with a discussion about the cars they've been driving — 2020 Porsche 911 Carrera 4, 2020 Alfa Romeo Giulia Quadrifoglio and the 2020 VW Tiguan. They shift gears to talk about the latest news gleaned from a press conference concerning the 2021 Supra, then, they reach into the mailbag to help a listener buy a performance car. Lastly, Greg has a chat with special guest Jean Jennings. Autoblog Podcast #626 Get The Podcast iTunes – Subscribe to the Autoblog Podcast in iTunes RSS – Add the Autoblog Podcast feed to your RSS aggregator MP3 – Download the MP3 directly Rundown Cars we're driving 2020 Porsche 911 Carrera 4 2020 Alfa Romeo Giulia Quadrifoglio 2020 Volkswagen Tiguan R-Line 2021 Toyota Supra news Spend My Money Jean Jennings interview Feedback Email – Podcast@Autoblog.com Review the show on iTunes Related Video:

Toyota mints 10-millionth vehicle in Kentucky

In 26 years, from 1988 up to now, the Toyota Motor Manufacturing Kentucky plant in Georgetown has built ten million vehicles - nearly enough for every citizen of Seoul, Korea or the nation of Hungary. The first car to roll off the line back when the claymation California Raisins were singing old Marvin Gaye hits and everybody wanted to know Who Framed Roger Rabbit? was a white Camry. The ten-millionth car to roll off the line among the Avalons and Venzas also produced there: a white Camry Hybrid.
Toyota has put $5.9 billion into the site since its inception, employment is up to 7,000 associates and will grow when Lexus ES350 assembly begins next year. Whereas car number one is a showpiece for the ages, one of the automaker's current associates will get to win the ten-millionth car in a blind drawing to be held this summer.
There's a press release below with more information on the impressive milestone.