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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."

Lexus GX, Toyota Land Cruiser Prado facelifts leaked

The Lexus GX and the Toyota Land Cruiser Prado, which isn't sold in the US, have gone without visual updates since the current generation was launched in 2009. But what appear to be patent filing sketches and pictures of the sibling sports utility vehicles' mid-cycle updates have been leaked on a Russian Land Cruiser Club forum.
Major changes to the GX's front end will be made to incorporate Lexus' signature grille. Gone are the awkwardly shaped headlamps and the soft-looking triple-slat grille. The sketch shows the Lexus with a new bumper, lower-profile headlights and a more aggressive, angular grille with one more slat and a gaping lower air-intake opening. The vehicle's profile looks unchanged, but the rear bumper will be reshaped slightly to fit new, better-integrated horizontal reflectors.
The Toyota gets a handful of styling updates as well, including a new front bumper with higher-profile headlamps that look a bit out of place to us. The Prado's profile also looks unchanged, but the rear end gets restyled taillights and a reshaped license-plate enclosure.

Toyota sees Camry share loss despite predicting increasing sales

Toyota may be set to lose share the midsize sedan market. While speaking with Automotive News, Toyota North America CEO Jim Lentz said that if his company kept pace with the current swell in the market for family four doors, Toyota would need to sell around 500,000 Camry models. "I'm not sure we can do much more than 400 [thousand] today," Lentz said.
But that doesn't mean Camry sales are shrinking - on the contrary, Lentz thinks Toyota will likely sell more Camry units in 2013 than it did in 2012, it's just that the company isn't keeping pace with segment's current explosion in popularity. Industry wide, midsized sedan sales have increased by 20 percent. "Are we going to lose [Camry] share? Probably so," Lentz said, "but we will continue to grow in raw volume."
Toyota sold 404,886 Camry units last year, and the company just revised its 2013 sales objective from 2.18 million units earlier this year to 2.2-million plus units, so while things are looking up for the brand and Camry sales may be on the rise, Toyota may not have the muscle to keep up its share in the sedan segment. Whether that's because of a production bottleneck or a predicted sales ceiling isn't clear. We've got a call in and will update this news item if/when we learn more.