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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."

Report: Daihatsu leaving European market

More than any other, two carmaking giants sit at the top of the industry: Toyota and General Motors. But while GM sells under a (shrinking but still) expansive range of brands, the Toyota Motor Corporation sells most of its vehicles under its own name. That doesn't mean that Toyota, however, doesn't have its own portfolio of subsidiaries. Here in the United States we have the youth-oriented Scion division, while Lexus handles its upscale offerings, and overseas there's Daihatsu.
The budget brand offers a range of small cars under its own name; most are hatchbacks, but there's also the Copen roadster and even a rebadged Camry called the Altis. You may have come across some of their offerings while traveling overseas, particularly in Europe, but that last part is about to come to an end, according to reports.
Word from across the pond is that Toyota plans to withdraw Daihatsu from the European market altogether. The move would reportedly take effect in 2013, and if it comes to pass, would follow similar withdrawals from the North American (1992) and Australian (2006) markets. Thanks for the tip, William!

J.D. Power study sees new car dependability problems increase for first time since 1998

For the first time since 1998, J.D. Power and Associates says its data shows that the average number of problems per 100 cars has increased. The finding is the result of the firm's much-touted annual Vehicle Dependability Study, which charts incidents of problems in new vehicle purchases over three years from 41,000 respondents.
Looking at first-owner cars from the 2011 model year, the study found an average of 133 problems per 100 cars (PP100, for short), up 6 percent from 126 PP100 in last year's study, which covered 2010 model-year vehicles. Disturbingly, the bulk of the increase is being attributed to engine and transmission problems, with a 6 PP100 boost.
Interestingly, JDP notes that "the decline in quality is particularly acute for vehicles with four-cylinder engines, where problem levels increase by nearly 10 PP100." Its findings also noticed that large diesel engines also tended to be more problematic than most five- and six-cylinder engines.