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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."

Recharge Wrap-up: Mazda, Subaru and Toyota PHEV, Nomadic Power grant

The next generation of the Toyota Prius Plug-in Hybrid looks to be important for Mazda and Subaru as well. Toyota will likely need to sell more of the new plug-in hybrid to meet stricter ZEV standards in California. That means it will get more extra electric range, as customers have been asking for. Subaru and Mazda will also have to adhere to the California standards beginning in 2018. Those two smaller automakers will likely license a plug-in hybrid powertrain from Toyota in order to fulfill compliance. Read more at Green Car Reports. Tesla is partnering with Dalhousie University to improve battery technology. Tesla signed a five-year research agreement with Dalhousie's Jeff Dahn, a lithium-ion battery researcher. Dahn and the 25 researchers in his lab will work with Tesla's Director of Battery Technology, Kurt Kelty, to increase capacity through improved materials. The collaboration could be important both for Tesla's automotive and stationary batteries. "Our research group's goal is to increase the energy density and lifetime of Li-ion batteries, so we can drive down costs in automotive and grid energy storage applications," says Dahn. Read more from Dalhousie University. Nomadic Power is receiving a European Commission grant worth ˆ2 million (about $2.26 million) for trailer-mounted mobile batteries. Nomadic Power's mobile batteries, called Nomads, have incorporated photovoltaic systems and can be used to extend the electric driving range of a plug-in vehicle, or to provide backup power to a home. The Nomads use an intelligent energy management system to learn and predict user behavior and manage the solar system based on weather forecasts. "We see a strong future in electric-powered mobility and an increasing use of renewable energy, photovoltaic power in particular," says Nomadic Power CEO Dr. Manfred Baumgaertner. "Our mobile batteries have great potential in these markets that recently got a significant shot in the arm by Tesla's announcements." Read more from Nomadic Power, and at Green Car Congress. Related Gallery 2012 Toyota Prius Plug-In: First Drive View 24 Photos News Source: Green Car Reports, Dalhousie University, Green Car Congress, Nomadic PowerImage Credit: Nomadic Power Government/Legal Green Mazda Subaru Tesla Toyota Technology Electric recharge wrapup

Toyota GT86 convertible could debut in March

The dates are lining up, now we wait to see how the badges align. Just before the Toyota GT 86/Scion FR-S/Subaru BRZ line-up was introduced at the Tokyo Motor Show last year, there was a report that Subaru was considering a convertible while Toyota wouldn't even comment on it. That got swapped around when earlier this year the chief engineer on Toyota's side said a convertible was coming, and then a Scion FR-S droptop was confirmed for early 2014.
Autocar now reports that the Toyota GT 86 convertible will make its first appearance at the 2013 Geneva Motor Show in March. In a car whose specs like weight, packaging, horsepower and center of gravity were all tightly controlled to get the most from the least, the changes necessitated by chopping the roof could make this a very different car. It's said to employ a fabric roof to keep a "small" weight gain check, and the suspension will be softened to work more harmoniously with the decreased body stiffness. And somewhere in all that the back seat and trunk space will need to take a hit.
In other news, Autocar says the hi-po GT 86 with some kind of capacitor system instead of batteries is being worked on for 2015.