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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."

Watch this video diary of a 900-hp Toyota Supra build

If you've ever looked at a car with nearly 1,000 horsepower and wondered why anyone needs that amount of thrust, you may want to take a look at the video below. In it, one gentleman details his descent into Toyota Supra madness, starting with a pristine factory example and stumbling down the rabbit hole of modification. What makes this particular clip interesting is just how honest the owner is as he explains the evolution of his car. He doesn't just prattle off a list of parts like he's reading the menu at an IHOP.
Instead, he painstakingly pulls us through the car's growth, detailing each iteration and what pushed him to the next stage of the build every time. From this point of view, it looks less like someone walked into a shop and lit a massive stack of $100 bills on fire and more like a quasi-logical progression of events. Or at least it does to me. You can check out the build in the video below, complete with plenty of Fast and the Furious references and racing. Win, win, win.

Submit your questions for Autoblog Podcast #319 LIVE!

We record Autoblog Podcast #319 tonight, and you can drop us your questions and comments regarding the rest of the week's news via our Q&A module below. Subscribe to the Autoblog Podcast in iTunes if you haven't already done so, and if you want to take it all in live, tune in to our UStream (audio only) channel at 10:00 PM Eastern tonight.
Discussion Topics for Autoblog Podcast Episode #319
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