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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."

Scion FR-S Convertible (in Toyota GT86 form) spied in South Africa

Though the eventual existence of a convertible version of the Toyota GT86 (and its Scion FR-S and Subaru BRZ versions for America) is a no-brainer, we've yet to get a glimpse of the real-deal car until now.
Spotted in Cape Town, South Africa, of all places, this completely undisguised GT86 convertible seems to be in a remarkably advanced state of development. The image seen here was obviously sniped from quite a distance and without the aid of a powerful lens, but we can still make out a production-ready looking piece of rear bodywork for the convertible top to hide away in, as well as a functioning trunk lid. It's hard to make out with any certainty, based on this evidence, but there does seem to be space retained behind the front seats for two, small rear chairs.
With the first car spotted, we'd expect to seem some more and better images of it flow through in the near future, and if not, Toyota has already confirmed a concept version for next month's Geneva Motor Show, dubbed FT-86 Open, so stay tuned. For now, click through to the FT86Club.com forum to have a slightly closer look at the images.

This classic Firebird restomod swallowed a Prius

It takes an unusual eye to look at a 1967 Pontiac Firebird and see the Toyota Prius hidden inside. But that's just the kind of eye that a creative mechanic known online as "Bill the Engineer" has. Bill is updating his old Firebird into a true classic for the 21st century and has documenting the changes over at Priuschat and EcoModder. The TL,DR version of the story: he's replacing the worn-out powertrain with the gas-electric hybrid one from a Prius V, because it turns out the two vehicles have almost exactly the same wheelbase. Bill, who's from Columbus, Ohio and doesn't want his full name used, said in his posts on the conversion project that he's made many memories with this vehicle since buying it back in 1979. Since then, a few moves, a few decades, and some time in storage meant that the car would no longer function as he wanted it to. As he wrote, "when it comes to mice in the vehicles IT IS WAR." His solution is to make new memories and making a greener vehicle, and so we wanted to ask him how things have been going. Bill's been traveling a bit recently, but told AutoblogGreen that he's now figuring out the next steps for this amazing and complicated project. "I always plan things out before I do them," he said. That's the only way something like this can work. ABG: I think we have to start with what gave you the inspiration for this project. Was it simply that you had the two cars and wanted to see them merged into one cool mashup, or was it something else? "One day my wife wondered out loud if the car could be converted into a hybrid... The rest is history." Bill: I have been the owner of my 1967 Firebird convertible since 1979 when I bought it for $750.00. I drove it for years and made many memories. Afterward it was in storage for many years during which time mice at their way into the car and trashed the interior and wiring. I started working on a conventional restoration but always ran into major problems with hidden corrosion, electrical issues and an engine on its last legs. The car was never going to be as nice as I wanted going the conventional route. One day my wife wondered out loud if the car could be converted into a hybrid like our two daily driver Prii. That got me thinking about how it could be done. The rest is history... ABG: It looks like you started in late 2014. Have things gone well since then, or has it been one hassle after another? What has been the biggest setback, and what were the biggest victories?