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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 to enter modern turbo four-cylinder era with Lexus crossover

Toyota has sat quietly on the sidelines as many of its competitors have armed themselves in recent years with lower-displacement turbocharged four-cylinder engines in an effort to gain better fuel efficiency numbers and flatter power curves. It's a strategy largely shared by fellow countryman Honda, who turned away from offering forced-induction four-cylinder models in North America after its first-generation Acura RDX failed to find buyers. Toyota itself has no lack of experience with turbo fours, having built some humdingers for cars like the MR2 and Celica All-Trac back in the 80s and 90s. It's also offered factory-warranted turbos through its TRD performance parts division more recently.
Now, Automotive News is reporting that the world's largest automaker is finally poised to rejoin the turbo-four production-car fray in North America, but it won't be a sports car that delivers the first force-fed punch, it will be a new small crossover model for Lexus. We first showed you spy shots of the NX last week in mule form, and Automotive News says the small softroader will carry a 2.0-liter turbo four in its engine bay when it rolls on to world markets in 2014 or early 2015. That model, the NX 200t, will be joined by the NX 300h, a hybrid variant. It isn't immediately clear when US buyers will see the turbo model, however, it's possible that the hybrid could bow first - the story quotes an anonymous company source suggesting that Americans might not see the engine offering until sometime in 2015.
AN further posits that the new 2.0-liter will likely supplant the company's 2.5-liter V6 in the IS sedan and the same-displacement four-cylinder in the Toyota RAV4, but does not indicate where the new engine will be built.

How many Toyotas are potentially affected by seat fabric problem?

When we reported yesterday on Toyota's stop-sale order of certain 2013 and 2014 models due to an issue with the fabrics on models with heated seats not conforming to flammability regulations, one of our many questions was how many vehicles were affected? More importantly, how many of those cars have already found homes?
Kelley Blue Book has the troubling statistics. Every 2013 and 2014 Avalon features heated seats. 6.2-percent of 2013 and 4.5-percent of 2014 Camry sedans, meanwhile, were sold with heated seats. That doesn't seem as bad as 100-percent of the larger Avalon, until you consider the Camry's huge volume - the 5.6-percent average still accounts for a lot of cars. Sienna minivans are heavily affected as well, with a total of 37-percent of 2013s and 46-percent of 2014s fitted with butt warmers. The stop-sale only affects 7-percent of 2014 Corolla models, but like the Camry, that number is rather misleading due to the sheer volume of cars Toyota moves. You can see the entire breakdown of percentages by clicking on the inset image.
According to Karl Brauer, a senior analyst for KBB, this problem comes at the worst possible time. "Given that much of the US is currently in the grips of a record cold snap, there's sure to be high demand for models with seat heaters," Brauer notes. The stop-sale order is a good first step, but it doesn't do anything to inform consumers who currently own the affected models and may, in these frosty temperatures, want to use their seat heaters. "Should owners of those vehicles stop using the seat heaters?" Brauer asked.