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NHTSA urges owners of recalled Takata airbag vehicles to take immediate action

The National Highway Traffic Safety Administration and the Department of Transportation are taking the unusual step of issuing a followup press release urging owners of certain recalled vehicles "to act immediately" to fix their cars and trucks. The problem in question concerns the repair campaigns for rupturing Takata airbag inflators issued in June and covers a long list of models from Toyota, Lexus, Honda, Acura, Mazda, BMW, Nissan, Infiniti, Buick, Cadillac, Chevrolet, GMC, Oldsmobile and Pontiac.
While NHSTA doesn't specifically say why the recall is vital in the new release, Toyota's own explanation in its newly announced renotification campaign earlier today sheds some new light on the topic. According to the Japanese automaker, in testing, Takata found a possible link between the rupturing airbag inflators and high humidity. NHTSA is advocating that all owners pursue repairs immediately if they haven't already done so already. This is especially crucial for those drivers especially in Florida, Puerto Rico, Guam, Saipan, American Samoa, Virgin Islands and Hawaii because of the humid conditions there.
We don't need to tell you how dangerous an inadvertent airbag deployment could be - even in a stationary vehicle - but adding to the Takata issue is fears that the deployment could lead to shrapnel being sprayed into the cabin.

Toyota responds to video of Highlander ramming house [w/video]

There are, as they say, two sides to every story, so after we posted a video on Monday showing what an owner claimed to be a case of unintended acceleration causing her Toyota Highlander to crash into a house twice, Toyota reached out to us revealing some additional information about the incident.
Following this crash, which took place back in November, Toyota had this Highlander inspected and pulled data from its Event Data Recorder (EDR), or Black Box as we've come to call it. Not only was this the first time we've seen a claim of unintended acceleration like this caught on video, but now, also a first, we have actual data showing what the vehicle itself recorded during this frightening ordeal.
Brian Lyons, Toyota Communications Manager for Safety and Quality, first gave us some information about the Highlander in question, including the fact that it was a 2012 model. The 2012 Highlander came from the factory with a brake override system, meaning it was not part of the company's initiative in 2010 to add the system to all 2011 models. Also, after looking at the data from the EDR, he said - as many of you pointed out in the comments for the previous post - that the "brake pedal was never touched." In the video, you can see that the crossover's brake lights never come on, and the EDR's data backs this up.

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."