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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."

Did Lexus make a BMW? Or did BMW make a Lexus? This and other 2017 surprises

It's that time of year again. The calendar is about to reach its end, Star Trek Cats 2018 is about to take its place, and I'm reflecting about all the cars that graced my driveway this year or summoned me to exotic places. You know, like Stuttgart or Phoenix. In 2017, I drove at least 57, and as I perused the list of them, I started to notice a common refrain: "This car surprised me." Most were pleasant surprises, but there were a few head scratchers and facepalms for good measure. In both cases, it was generally the result of car companies seemingly trying to break out of an existing mold. Nowhere was that more apparent than the pair of Lexuses slathered in Infrared paint: The LS 500 that left me this week and the LC 500 that was my favorite car of 2017. Though Lexus has been trying to shake its crusty, gold-packaged reputation for some time now, its efforts always seemed like an old man choosing Hollister to redo his wardrobe after realizing it hasn't been updated since 1987. I fell in love with the LC, genuinely floored by its near-perfect take on the GT. It's characterful in sound, appearance and tactility. It was at home in the city, in the mountain and on the open road. It was both comfortable and thrilling, and after driving the mechanically related LS 500, I can report that the LC's talents aren't an outlier. The LS 500's turbo V6 may make different noises than the LC's naturally aspirated V8, but it nevertheless invigorates the cabin when the car is placed in Sport+ mode. The steering is truly communicative, body motions are kept in miraculous check, and I absolutely forgot I was in an enormous luxury limo ... and a Lexus one at that. It was everything that the BMW 530e was not. I drove that on the exact same roads and was utterly bored the entire time. Generally doughy, lifeless steering, more distant than Planet 9. And no, the plug-in hybrid powertrain had nothing to do with that. At least it shouldn't. The Porsche Panamera S e-Hybrid I also drove this year proves that, as do the Hyundai Ioniqs, which are surprisingly adept and fun little cars regardless of what powers their wheels (Hyundai + hybrid = fun really blew me away). I would drive that Lexus LS F Sport over the BMW 5 Series any day of the week, which seems like a shocking thing to say in relation to either car. While Lexus is seemingly breaking out of its old crusty mold, BMW seems to be climbing into one.

Mini Minor to be co-developed with Toyota

It was back in 2011 when Mini first showcased the prospect of an even smaller hatchback with the Rocketman concept at the Geneva Motor Show. In the nearly four years since, parent company BMW has hemmed and hawed on the possibility of putting it into production, but the latest word from Europe has it that the project is a go. According to Automobile magazine, Mini is realigning its product portfolio into five pillars: the essential hardtop we've already seen (available in two/three- and four/five-doors), the convertible, the upcoming new Clubman wagon (coming this summer with full-size auxiliary suicide doors on both sides), the next-gen Countryman crossover in 2016 and two new model lines. One will be the production version of the Superleggera roadster concept, earmarked for 2018. The other will be the Minor, a smaller city car reviving a long-gone model name and presaged by the aforementioned Rocketman concept. But for that last one, Mini won't go it alone. To develop the mini Mini, BMW will reportedly turn to its partnership with Toyota. The relationship is already set to yield a new Supra and Z4 and share fuel cell and other technologies. But this would broaden the partnership to include a small hatchback. However rather than use the existing (or next-gen) Aygo, which is already built under joint venture with PSA Peugeot Citroen (with which BMW previously had a joint engine venture), word has it that the BMW and Toyota will develop a new platform for the project – one that will be used by both partners. The new product plan doesn't leave much room for the Mini Coupe and Roadster (which have already been discontinued), for the Paceman three-door crossover (which will suffer the same fate) or for the projected seven-seater minivan. But the addition of the new Superleggera roadster and super-mini Mini aren't likely to leave us wanting for either. Related Video: