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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 launches new Pixis Epoch kei car in Japan

Kei cars may be small in size, but they're big business in Japan. The latest arrival to the category is the little hatch you see above, the Toyota Pixis Epoch.
It's the fourth vehicle produced by the Daihatsu division but sold under the Toyota brand. As with other keis, power comes from a 660cc engine. It's mated to a continuously variable transmission driving either just the front wheels or all four. In both configurations, the Pixis Epoch features a stop-start system that helps its emissions and fuel efficiency figures come in well below even the Japanese government's stringent standards.
The whole package measures just 3,395 mm (133 inches) long, 1,475 mm (58 inches) wide and 1,500 mm (59 inches) tall, but offers a relatively spacious and utile interior, plus a tight turning radius of just 4.4 meters. Pricing ranges from 795,000 to 1.2 million yen - that's less than $10,000 (and no more than $15k). Further details in the press release after the jump.

Toyota fires bullets into hydrogen fuel tanks, shoots down EV supporters

Many gearheads will remember that the 1970s-era Dodge Dart's claim to fame was that its motor was so durable (though not necessarily powerful) that one could shoot bullets into the engine block. Decades later, Toyota has taken a page out of that testing process. "Personally, I don't care what Elon [Musk] says about fuel cells." With some industry members and analysts questioning both the viability and durability of hydrogen fuel-cell electric vehicles, Toyota executive Bob Carter, speaking at the Automotive News World Congress this week, says the Japanese automaker went all Clint Eastwood on the fuel tanks of a fuel-cell prototype. Carter says that bullets from a small-caliber gun bounced off the carbon-fiber tanks, and that .50-caliber bullets barely made dents. The shoot-out motif kept going when Carter name-checked executives from Tesla, Nissan and Volkswagen in saying that he didn't care if other automakers question the future of fuel-cell vehicles. As you can see in the prepared text of Carter's speech below, he said, "Personally, I don't care what Elon [Musk], Carlos [Ghosn] or Jonathan [Browning] say about fuel cells. If they want to 'plug in and tune out' other technologies, that's fine." After debuting it in Tokyo late last year, Toyota showed off its FCV fuel-cell concept vehicle at the Detroit Auto Show this week as it get ready to start sales "around 2015." The car has a 300-mile range and should be priced somewhere between $50,000 and $100,000. Autoblog drove Toyota's fuel-cell prototypes last year, and you can read our impressions here. 2014 Automotive News World Congress- Bob Carter January 14, 2014 As prepared for: Automotive News World Congress Tuesday, January 14, 2014 Bob Carter, Senior Vice President, Automotive Operations, Toyota Motor Sales, U.S.A., Inc. _________________ Thanks, Keith and good afternoon everyone. You know, I've been in the car business for more than 30 years, but I'm more excited about it now than EVER before Why? Because for the first time in Toyota's history, we did something here we've NEVER done before. We shocked people by unveiling two great looking, fun-to-drive cars that blow a hole in the theory that Toyota only builds "appliances". Just yesterday, we unveiled Toyota's newest concept, the FT-1 sports car. I'm already getting people asking me when they can get their hands on one. The FT-1 represents the latest in our heritage of sports cars like the 2000GT, Celica, Supra and most recently, the FR-S.