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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 FT-86 Open Concept would make a mighty fine droptop FR-S

There's nothing wrong with going topless. And Toyota is proving that its FT-86 (read: Scion FR-S/Toyota GT86/Subaru BRZ) coupe is just as excellent with its roof removed. It may only be a concept, but this FT-86 Open previews a new droptop from the Japanese automaker to round out the Toyobaru sports car family. We're finally getting the chance to see the open-air FT-86 in person here at the Geneva Motor Show, and we're already yearning to take it canyon-carving.
Interestingly, the FT-86 retains the Toyota coupe's two-plus-two seating arrangement (we'd prefer a proper roadster setup here), but things still look good for this droptop two-door. We'll be curious to see how the car looks with its folding soft top in place (operated by fancy-shmancy electronics, by the way).
As for production intent, rumors have been flying about a production Scion FR-S convertible, but until we hear it directly from Toyota. Consider our hopes in check but our fingers crossed.

Driving the Toyota Supra, Honda Passport and BMW 3 Series | Autoblog Podcast #582

In this week's Autoblog Podcast, Editor-in-Chief Greg Migliore is joined by Green Editor John Beltz Snyder and West Coast Editor James Riswick. First, they talk about the cars they've been driving, including the Honda Passport, BMW 330i and Audi RS5. They follow up with notes about driving the Toyota Supra and 86, and whether Toyota's new sports car strategy makes sense. Then they discuss the news, including the Ferrari SF90 Stradale plug-in hybrid, a possible Renault-FCA merger, death rumors for the Jaguar XJ and thoughts on the upcoming Chevy Trailblazer. Autoblog Podcast #582 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: 2019 Honda Passport 2019 BMW 330i 2019 Audi RS5 Sportback Toyota Supra, 86 and the company's sports car strategy In the news: Ferrari SF90 Stradale FCA and Renault Jaguar XJ going away? Chevy Trailblazer Feedback Email – Podcast@Autoblog.com Review the show on iTunes Related Video: