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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 creates GT86 concept inspired by Initial D

Everyone has a favorite movie or TV car of their youths. The love of these cars can ignite a lifelong passion for automobiles. Some lust for the sharp, stainless steel DeLorean DMC-12 from Back to the Future or the decked-out Aston Martin DB5 from Goldfinger. For anime and manga fans, it's the panda-colored Toyota AE86 Sprinter Trueno from the Initial D manga and anime series. Toyota, recognizing the significance of the that car, meticulously reimagined it for a modern audience, basing it on the UK market GT86. The GT86, sold in the United States as the Scion FR-S and soon to be rebadged as the Toyota 86, is considered by some to be the spiritual successor to the rear-wheel-drive AE86 Corolla from the 1980s. Both are reasonably affordable, lightweight cars with a propensity for oversteer. The original AE86 from Initial D was a highly modified but realistic drift machine. The amazing feats of that tofu delivery car as it raced everything from Mazda RX-7s to a Honda S2000 turned the little Toyota into a cult icon. That AE86 itself was inspired by the personal vehicle of Japanese racing driver Keiichi Tsuchiya. Tsuchiya served as both an inspiration and supervisor for Initial D. Many of the modifications on the Initial D car, like the TRD carbon-fiber hood and Fujitsubo exhaust, car were exactly the same as Tsuchiya's real-life vehicle. Toyota is no stranger to crafting modern incarnations of classic vehicles. Last year the company created a Back to the Future Tacoma. Toyota's Initial D concept car uses the same parts wherever possible. Like the original, it has a carbon-fiber hood, Fujitsubo exhaust, and black Watanabe F8 wheels. The suspension, lights, and body have all been modified. Even small details like the engine cover and door handles were modified to recall the fictional car. The end result is a fantastic creation that pays great homage to the original. Toyota went as far as hiring UK manga artist Sonia Leong to design a series of backdrops that place the car in the same action shots as the original series. While this one-off vehicle is just a concept, most of the parts are available to purchase for fans who may be inspired to create their own version. Toyota's concept will be on display at various motoring shows across the UK this summer. Related video: Featured Gallery Toyota Initial D GT86 TV/Movies Scion Toyota Coupe toyota gt86 toyota 86

Oh, Kei Go: Toyota set to enter JDM minicar market?

Toyota is looking to get bigger... by going smaller. The Japanese automaker is looking to enter the kei car market, a popular segment in its homeland. Kei cars are small vehicles with restrictions on length (11.15 feet), width (4.86 feet), engine size (660 cubic centimeters) and power output (63 horsepower). Currently, Toyota is the only Japanese automaker not producing vehicles for this segment, but that is set to change, according to a report from The Wall Street Journal.
Thanks to its relationship with Daihatsu, Toyota can jump right into the kei car game. Daihatsu is one of the largest producer of kei vehicles and it is currently owned by Toyota.
Although kei cars are restricted in terms of size and power, they are not restricted by technology. Automakers utilize different drive configurations, powertrains and amenities to keep their cars fresh. Daihatsu and Toyota plan to work together to produce Toyota-branded kei cars. The two companies will utilize Toyota's knowledge of electric and hybrid systems to produce efficient little vehicles for the Japanese market.