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Toyota recalling 1.9M Prius models globally for software update

Toyota has announced a set of voluntary recalls covering 960,000 Prius, RAV4, Tacoma and Lexus RX350 models in the United States to address two separate issues. Worldwide, Toyota will have to recall a total of 1.9 million Prius cars.
The Prius recall affects about 700,000 2010-2014 models in the US, due to a fault in the motor/generator control ECU and hybrid control ECU software. It says that the current software could result in high temperatures on certain transistors and possibly damage them. When it fails, the error forces the car into failsafe mode. Toyota says that in rare circumstances, it could even shut the hybrid system down while the car is being driven.
Toyota spokeswoman Shino Yamada told Automotive News that the software update should take about 40 minutes, and dealers would start to be notified about affected vehicles today. She also told them that the first reported glitch occurred in May 2011 in the US when the system overheated and the car entered failsafe mode. The affected cars were built between March 2009 and Feb. 5, 2014, according to Automotive News. Toyota says that it has received no reports of accidents or injuries caused by either fault.

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."

Ford only automaker to make 2012 Buzz Rankings, Toyota most improved

Ford landed itself a spot among the top 10 brands in the 2012 Buzz Rankings. The annual index scores 1,100 brands in 41 categories to determine which nameplates had the most positive buzz throughout the year.
For the third year in a row, Subway took the top honors overall with a score of 40.3, and Ford was the only automaker to break into the top 25 by earning a sixth-place finish overall. The manufacturer earned a score of 32.1 points, which was enough to push it up one spot from the 2011 Buzz Rankings. Honda managed 21.2 points overall, which is still well behind 25th-place Kohl's at 26.5 points. Toyota, Volkswagen and BMW all round out the top five automakers.
The 2012 Buzz Rankings also keep track of which brands improved the most over the past year, and this year, Toyota was the manufacturer with the largest leap forward. The Japanese automaker jumped from just 14 points in 2011 to 20.5 in 2012. Chrysler, Kia, Dodge and Volkswagen all saw sizable steps forward as well. Be sure to head over to the Brand Index site for more information.