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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 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 sold a million hybrids in last nine months, 6M since 1997

Toyota's first hybrid model – the Prius – went on sale in 1997 in Japan. It took 14 years for the company to see a cumulative total of three million hybrids (a mark reached in March 2011). Today, Toyota announced that its global sales figures of all of its gas-electric models (and there are a lot of them now, including ones we've barely heard of here in the US, like the Crown Majesta or the Harrier Hybrid) have reached six million. Toyota calculates that all those hybrids have saved 41 million tons of CO2 emissions from entering the atmosphere. Toyota's ever-increasing hybrid sales pace means the company sold as many in the last three years as it did in the first fourteen. As you can see in our chart, the trendline shows that we'll hit the next-million mark in short order. In fact, Toyota says that it sold a million hybrids in the last nine months, the shortest time it has ever taken the automaker to sell that many hybrids. Part of the reason is that there are 24 hybrid Toyota and Lexus models available around the world, and Toyota says another 15 will be coming in the next two years. Anyone want to guess when Toyota will hit seven million? August? Worldwide Sales of Toyota Hybrids Top 6 Million Units Toyota City, Japan, January 15, 2014-Toyota Motor Corporation announces that cumulative global sales of its hybrid vehicles topped the 6 million unit mark as of December 31, 2013, reaching 6.072 million units1. The latest million-unit milestone was achieved in the fastest time yet for Toyota, taking just nine months. Helping mitigate the environmental effects of vehicles is a priority at Toyota. Based on its belief that environment-friendly vehicles can only truly have a positive impact if they are widely used, Toyota has endeavored to encourage the mass-market adoption of hybrid vehicles. As of this month, Toyota sells 24 hybrid passenger car models and one plug-in hybrid model in approximately 80 countries and regions around the world. Furthermore, within the next two years, Toyota will launch a total of 15 new hybrid vehicles worldwide, including the new "Harrier Hybrid" in Japan on January 15 and the new "Highlander Hybrid" in the United States in the near future. Toyota will continue augmenting its product lineup even further and increasing the number of countries and regions where it sells hybrid vehicles.