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Toyota, Lexus expanding Takata airbag recall, re-notifying customers

Toyota is re-notifying owners and expanding its Takata airbag inflator recall for some regions. The renewed campaign covers 247,000 examples of the Toyota Corolla, Matrix, Sequoia, Tundra and Lexus SC430 that are located in southern Florida, along the Gulf Coast, Puerto Rico, Hawaii, the US Virgin Islands, Guam, Saipan and American Samoa. All of the models come from the 2001-2004 model years and have potentially faulty Takata-made inflators on the front passenger side. According to the company, testing shows the problem warrants "immediate action," and its press release says, "this action intensifies Toyota's efforts to reach customers and remedy previously recalled vehicles, and a small number of newly included vehicles."
According to Toyota, it submitted some recalled inflators to Takata for testing, and it found a high probability of rupturing in high humidity areas. The automaker said it had no reports yet of injuries or fatalities related to the problem.
This is Toyota's third inflator recall this year. In June, it called in for repair the same vehicles from the 2003-2005 model years in high-humidity areas, and it conducted a separate campaign nationwide for the parts in additional models. In April 2013, it also announced a fix campaign for 1.73-million vehicles worldwide for the same issue.

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 nearing $1B settlement of unintended acceleration criminal probe

According to those all-too-nebulous "people familiar with the matter," Toyota is close to a settlement with the US federal government to end a criminal probe over its long-running unintended acceleration fiasco. Though Toyota has never admitted guilt, the deal could reportedly crest a billion dollars and would likely include a criminal deferred prosecution agreement, and while we're not legal experts, The Wall Street Journal explains that such a deal would "[force Toyota] to accept responsibility while avoiding the potentially crippling consequences of federal criminal convictions."
The report from WSJ also suggests that Toyota is facing charges that it "made false or incomplete disclosures" to various government agencies regarding possible defects to its cars. Such charges may include mail and wire fraud violations. Toyota has already paid out fines totaling $66.2 million to the National Highway Traffic Safety Administration because it failed to report safety defects in a timely manner.
This deal with the federal government is not related to the billion-dollar class-action settlement reached with Toyota owners over falling vehicle values, and it's also different from the roughly 400 lawsuits still in courts alleging personal injury of wrongful death due to cases of unintended acceleration. In other words, don't expect to hear the end of such courtroom verdicts and settlements anytime soon...