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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."

2013 Toyota Avalon Hybrid

People, us included, make a big stink about the importance of family sedans. There's no doubt they're critical - they represent a huge slice of the market's annual sales and profits. However, despite accounting for far fewer transactions than the midsize sedan segment, the fullsize sedan is getting attention from manufacturers now that our market's entire lineup of those (slightly) smaller four-doors has turned over in the last two years or so. As most of the fullsize segment's mainstays derive a fair bit of their platform and powertrain technologies from their midsize cousins, these larger four-doors offer the potential for fatter profit margins, too. And with the newly stylish duds found on many of the industry's most successful midsize sedans, it's only right that automakers no longer think about fullsizers as big, squishy, vanilla family haulers with flat seats, vague steering and a thin layer of 'luxury' in the form of faux wood trim.
As manufacturers have again started diving into large sedans feet-first, the cars themselves have become sharper. The interiors are now of a higher quality and loaded with tech, while the exteriors have become further extensions of each manufacturer's design language. There's perhaps no greater example of this than the Chevrolet Impala and Ford Taurus, two models that evolved from subpar offerings into market leaders. This segment-wide transformation happened quite quickly, whether because of coincidental timing or because manufacturers are trying to get more out of their big cars, recognizing they account for a small portion of overall sales (just 3.5 percent of the new-car market in the first half of 2013).
The 2013 Toyota Avalon Hybrid is one such vehicle. We remarked on the changes to the V6 variant last year, and while we previously had a quick steer of the gas-electric hybrid, we figured the new model was worth a closer week-long look.

Child cobalt miners: Automakers pledge ethical minerals sourcing for EVs

BERLIN - Leading carmakers including Volkswagen and Toyota pledged on Wednesday to uphold ethical and socially responsible standards in their purchases of minerals for an expected boom in electric vehicle production. Demand for minerals such as cobalt, graphite and lithium is forecast to soar in the coming years as governments crack down on vehicle pollution and carmakers step up their investments in electric models. To cover its plans for more than 80 new models by 2025, Volkswagen alone is looking for partners in China, Europe and North America to provide battery cells and related technology worth more than 50 billion euros ($59 billion). Talks with major cobalt producers, including Glencore, at VW's Wolfsburg headquarters last week ended without a deal. More than half of the world's cobalt comes from the Democratic Republic of Congo, a country racked by political instability and legal opacity, and where child labor is used in mines. On Wednesday, a group of 10 leading passenger-car and truck manufacturers announced an initiative to jointly identify and address ethical, environmental, human and labor rights issues in raw materials sourcing. The partnership dubbed "Drive Sustainability" consists of VW, Toyota Motor Europe, Ford, Daimler, BMW, Honda, Jaguar Land Rover, Volvo Cars and truckmakers Scania and Volvo. The alliance "will assess the risks posed by the top raw materials (such as mica, cobalt, rubber and leather) in the automotive sector," said Stefan Crets of the CSR Europe business network. "This will allow Drive Sustainability to identify the most impactful activities to pursue" to address issues within the supply chain.Reporting by Andreas Cremer.Related Video: Image Credit: Michael Robinson Chavez/The Washington Post via Getty Images Green BMW Ford Honda Jaguar Land Rover Mercedes-Benz Automakers Toyota Volkswagen Volvo Green Automakers Green Culture Electric Scania ethics mining