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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 and Lexus recall models for inadvertent airbag deployment

The Basics: Toyota will recall 320,000 examples in the US of the 2003-2006 Land Cruiser, 2004-2006 4Runner, 2005-2006 Tundra and Sequoia, 2003-2006 Lexus LX470, and 2004-2006 GX470. The Problem: The curtain shield airbags that come down from the roof can inadvertently deploy shortly after vehicle startup. This is due to improper programming of the airbag control module. Injuries/Deaths: "Toyota is not aware of any crashes caused by the condition. We have received reports alleging injuries such as abrasions and ringing in ears," company spokesperson Cindy Knight told Autoblog. The Fix: Toyota and Lexus dealers will replace the airbag control module with a new part, which will have improved programming. If You Own One: Toyota and Lexus will notify affected owners by mail early this month. Related Video: Toyota and Lexus Recall Certain Land Cruiser, 4Runner, Tundra, Sequoia, LX, and GX Vehicles February 02, 2016 TORRANCE, Calif., February 2, 2016 – Toyota Motor Sales, U.S.A., Inc. today announced that it is conducting a safety recall of approximately 320,000 Model Year 2003-2006 Land Cruiser; 2004-2006 4Runner; 2005-2006 Tundra and Sequoia; 2003-2006 LX 470; and 2004-2006 GX 470 vehicles. The involved vehicles are equipped with side Curtain-Shield-Airbags (CSAs) which deploy from the roof in the event of certain types of crashes. Due to improper programming in the airbag control modules, there is a possibility that, under certain specific and limited conditions shortly after startup, the CSAs and seat belt pretensioners could activate when not necessary. Unexpected activation of the CSAs could increase the risk of injury to the occupant. All known owners of the involved vehicles will be notified by first class mail. Toyota and Lexus dealers will replace the airbag control module with one which has an improved programming at no cost to owners. Information about automotive recalls, including but not limited to the list of involved vehicles, is subject to change over time. For the most up-to-date Safety Recall information on Lexus, Toyota and Scion customers should check their vehicle's status by visiting http://www.toyota.com/recall and entering the Vehicle Identification Number (VIN). Safety Recall inquiry by individual VIN is also available at the NHTSA site: safercar.gov/vin. For any additional questions, customer support is also available by calling Toyota Customer Service at 1-800-331-4331 or Lexus Customer Service at 1-800-255-3987.

Would you pay $17 a month to give your older Ford connectivity?

When it was first introduced in 2007, there was nothing like the original Ford Sync system, since it allowed car owners to connect and use a portable device better than anything that came before it. And because it was a brought-in/tethered and software-based system, Sync leveraged a device's connectivity and was easily updated. It took competitors awhile to catch up: Toyota Entune wasn't available until 2011, and Chevy MyLink didn't roll out until 2012. But now Ford is the one playing catchup since it stuck with the brought-in strategy while most other automakers were quicker to add connectivity via an embedded cellular modem. Ford initially installed 2G/3G modems in its small fleet of electric and plug-in electric vehicles starting in 2012 so that owners could keep tabs on charging. Embedded connectivity came to Lincoln in 2014, and Ford began adding onboard 4G LTE via Sync Connect to select cars starting with the Escape in 2015. To get more cars connected more quickly, last week the automaker rolled out its FordPass SmartLink solution that plugs into the OBD port of 2010 to 2017 model year vehicles. This lets owners retroactively get onboard Wi-Fi, set up a "geo-fence" to keep tabs on a car's location, receive vehicle health reports and allows remote engine starting and door locking/unlocking using a smartphone app, among other features. But to connect older Ford vehicles will cost owners $16.99 a month for two years, not including installation. Ford throws in 1 GB of data or a 30-day trial, whichever comes first, after which owners have to add the vehicle to their Verizon shared data plan, which supplies connectivity for SmartLink, or establish a new account. (Disclosure: Autoblog is owned by Verizon.) By comparison, GM's 4G LTE data plans start at $10 a month for 200 MB and goes up to $30 for 3 GB, and owners can also add a car to an AT&T shared-data plan. But OnStar doesn't have a separate monthly subscription for the embedded modem or an installation charge, and standard features via the RemoteLink Mobile App are free for the first five years of ownership. FCA's Uconnect Access service also uses an embedded modem to provide similar telematics features for $20 per month following a free one-year trial, while a la carte in-car Wi-Fi is offered for $10 per day, $20 per week or $35 per month.