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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, Lexus will offer low-cost automated braking system

First, a technology gets better, then it gets a lot better, then it gets less expensive, then it gets a lot less expensive. Advanced driver safety and convenience systems are about to make that last step thanks to Toyota. Centered around a pre-collision braking system, there will be three suites of driver aids known as Toyota Safety Sense C (TSS C) for compact cars, Toyota Safety Sense P (TSS P) for midsized and premium cars, and Lexus Safety System+ (LSS+) for the luxury brand. TSS C pairs a camera with laser radar to provide a pre-collision system that prompts the driver to brake if it detects an impending accident, and can supply additional braking force and automatically brake between seven and fifty miles per hour. There are also Lane Departure Alert and Automatic High Beam. TSS P pairs a camera with more precise millimeter-wave radar. Starting with the three functions in TSS C, it adds pedestrian pre-collision capability and adaptive cruise control. This one will be available first, coming on the new RAV4 Hybrid and Avalon. TSS - either C or P - will expand to three more vehicles by the end of the year. The wallop is in the price: TSS C will be a $300 option, TSS P will cost $500. Compare the Ford Fusion SE, for instance - it's Driver Assistance Package comes with Lane Departure Warning, Automatic High Beams, it has Lane Keep Assist, Blind Spot and Cross Traffic Detection that neither TSS has, but doesn't have any autonomous braking feature. It costs $1,200, but requires you to add the Technology and Luxury Packages for a total price of $3,165. If you want Autonomous Cruise Control, that's another $995, for $4,160 in total. Instead of $300 or $500 on the Toyota. Lexus' LSS+ will come first on the new RX then spread to four more models by the end of this year, and cost between $500 and $635 to add as an option. It also uses a camera and millimeter-wave radar for its vehicle and pedestrian pre-collision system, lane departure warning and lane keep assist, automatic high beam, and auto cruise control. The similar package on a BMW X5, with no pedestrian component, is $1,200. Toyota says both safety suites will eventually be on "nearly all" of it products and all trim levels by the end of 2017.

Recharge Wrap-up: First EV to attempt Dakar Rally, Mazda makes bioplastic parts

Zap and Jonway Auto brought their Urbee EV and their new Falcon A-380 SUV to the Peru Motor Show in Lima. Jonway sells its SUV and minivan in Lima through Dai-Ichi Motors, which displayed the cars at the show. According to the companies, their cars "received tremendous interest from the public," including private citizens as well as groups who would use the EVs for security guard service or campus use. Read more in the press release below. California is the US leader when it comes to EVs. In 2013, California had 70,000 battery electric and 104,000 plug-in hybrids. The state boasts almost half of the country's electric vehicles, thanks largely to state and local EV incentives that go beyond the federal tax rebate. California also leads the way in legislation, and nine other states have adopted California's ZEV mandate. Washington, Maryland, Georgia and DC also have their own EV incentives, while some utility companies also offer benefits for EV owners in other states. Still, EV sales have only made up about 0.7 percent of new vehicle sales in 2014. Read more at the US Energy Information Administration website. Toyota will be using landfill gas to help power its Kentucky manufacturing facility. Beginning in 2015, Toyota's Georgetown assembly plant will use electricity converted from landfill-sourced methane gas from Waste Services of the Bluegrass. It will provide enough energy to produce 10,000 vehicles each year. Plus it diverts methane - a greenhouse gas - from entering the atmosphere and helps improve the local air quality. Learn more in the video or Toyota's press release below. Mazda has developed a plant-derived bioplastic for making exterior and interior parts. The dyed plastic doesn't require painting, and it reduces petroleum consumption and carbon emissions in the manufacturing process. The bioplastic will be used for interior parts in the all-new MX-5 before being put into use on the exterior of future vehicles. Mazda will display prototype parts at the Eco-Products 2014 exhibit in Tokyo. Read more in the press release below. Acciona will enter the first-ever zero-emissions vehicle (pictured) to compete in the Dakar Rally. The vehicle uses an electric motor and lithium ion batteries, as well as solar panels to power telemetry and security systems. The Dakar Rally will take place from January 4 through 17 through Argentina, Chile and Bolivia. See Acciona's Dakar EV in the video and read more in the press release below.