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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."

Honda, Nissan, and Toyota expand Takata recall by millions worldwide

Honda, Nissan, and Toyota are expanding their global Takata airbag inflator recalls to cover millions of additional vehicles. Toyota alone is adding about 5 million vehicles to its campaign globally, and over 600,000 of those are in the US, according to Automotive News. Nissan's expansion includes an estimated 1.56 million cars worldwide, including about 326,000 in North America, but the exact models from the company are not yet known. According to Automotive News, Honda has also announced plans to increase the scope of its campaign but hasn't yet disclosed specific models, total numbers, or their location. Company spokesperson Chris Martin tells Autoblog that none of these vehicles are in the US, though. In the US, Toyota is replacing the driver's side front inflators on 160,000 examples of the 2004 and 2005 RAV4 nationwide. It's also swapping out the front passenger side parts for 177,000 units of the 2003 and 2004 Tundra (pictured above) and 2004 Sequoia. The automaker is also expanding its regional recalls in high-humidity areas to include the passenger-side inflators of 300,000 more vehicles. In total, the affected models are 2005-2007 model-year Corolla, Matrix, Sequoia, and Lexus SC; plus the 2005-2006 Tundra is included, as well. All of the states that are covered by this campaign are listed in Toyota's announcement, below. In a statement to Autoblog, Nissan said that it's currently working with the National Highway Traffic Safety Administration on this campaign. "We expect to have a more formal statement and additional information by Friday, May 15," the company said. TOYOTA EXPANDS TAKATA AIRBAG SAFETY RECALLS TORRANCE, Calif., May 12, 2015 – Toyota Motor Sales, U.S.A., Inc. today announced that it is expanding its recalls involving Takata air bag inflators. First, Toyota will conduct a recall to replace Takata-supplied driver front airbag inflators on approximately 160,000 model year 2004 and 2005 RAV4 sport utility vehicles. The inflators could potentially be susceptible to rupture when deployed in a crash, increasing the risk of injury to vehicle occupants. For similar reasons, Toyota will expand two existing recalls for Takata-supplied front passenger airbag inflators, namely: Toyota's nationwide recall launched in April 2013 will expand to include approximately an additional 177,000 model year 2003-2004 Tundra and model year 2004 Sequoia vehicles.

Autotrader picks best cars for 2015's college grads

Summer is here and the school season is winding to a close. That means millions of students will be graduating college and (hopefully) entering the workforce. For many, that will mean buying a new car suited to the new stage in life into which they will now be embarking. That can be a bewildering choice, especially for someone who's never bought a car before. Fortunately, Autotrader has come up with a short list of recommended cars – new and used – which it recommends to the graduating class of 2015. Among the site's top choices are some compelling crossovers and hatchbacks, including the Buick Encore, Chevy Trax, and Jeep Renegade, as well as the Honda Fit, Nissan Versa Note, Mazda3 and Fiat 500. Can't stretch to buying new, or don't see the point? Autotrader has also identified the Toyota Camry, Ford Fusion and even the Lexus IS as smart buys in the certified pre-owned category. "Any time someone goes through a major life change, such as graduating college, they need to determine if their current ride makes sense for their lifestyle, from both a financial and functional perspective," says Autotrader editor Brian Moody. "For example, while that hand-me-down SUV from your parents was nice when you turned 16, you may want to opt for a safer, more fuel-efficient car as you transition into the working world." Autotrader Names 10 Best Cars for Recent College Graduates ATLANTA, May 28, 2015 /PRNewswire/ -- For many, graduating college is a milestone like no other – it represents a new chapter, a proud accomplishment and, fortunately or unfortunately, financial independence. Luckily for graduates who are in the market for a new car to suit their post-college lifestyle, Autotrader's expert editors say now is a great time to make a purchase, as dealerships are flush with affordable models that are fun, fuel-efficient and thoughtfully designed. Autotrader Logo "Any time someone goes through a major life change, such as graduating college, they need to determine if their current ride makes sense for their lifestyle, from both a financial and functional perspective," said Brian Moody, site editor for Autotrader.