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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 maintains world's largest automaker crown, GM and VW close behind

Toyota still holds the title of World's Largest Automaker. The Japanese automaker ceded the claim to General Motors in 2011 following a series of natural and man-made disasters that stifled production in Asia. Production is back up to full speed and, coupled with the introduction of a new Camry midsize sedan, Toyota retook the title in 2012 and has so far been able to keep it by selling 2.43 million vehicles in the first quarter of 2013.
The race is still tight - General Motors reports sales of 2.36 million vehicles, earning it the second spot globally with Volkswagen's 2.27 million sales nabbing the German automaker third place. It's not all smooth sailing for Toyota, either, as the brand's first-quarter figures were down 2.2 percent when compared to last year. GM posted a 3.6-percent gain and VW managed a 5.1-percent gain over the same period.
Sales in China may be a deciding factor as to which automaker performs best in 2013. Toyota's figures were down 13 percent in China. Meanwhile, GM and VW are continuing their upward trajectories in the crucial Chinese market.

Toyota asking NHTSA for waiver on 206K vehicles

Toyota has filed a petition with the National Highway Traffic Safety Administration asking for a waiver to avoid recalling about 206,271 2012-2014 Camry, Avalon, Corolla, Sienna, Tundra and Tacoma vehicles, some of its most popular models. The affected vehicles contain seat heaters that might not meet government flammability standards. Toyota says in the waiver that "the chance of fire or flame induced by a malfunctioning seat heater is essentially zero," according to The Detroit News. The automaker notes the part makes up less than one percent of the seat's weight.
Initial reports of the problem arose in late January when Toyota issued a stop-sale order for 2013 and 2014 model year versions of those vehicles. The automaker says that there have no been reports of fires or injuries in the affected cars, and the problem was discovered during testing by the South Korean government, according to The Detroit News.
We've reached out to Toyota for comment on this development and are awaiting a reply. We'll update this post if and when we hear back.