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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 reaffirms commitment to body-on-frame SUVs

Toyota sold 121,055 Highlander CUVs in 2012, according to Automotive News. By comparison, it sold 78,457 examples of four different body-on-frame, truck-based SUVs (4Runner, FJ Cruiser, Sequoia and Land Cruiser). One could argue then, that the traditional SUVs aren't pulling their weight from a sales perspective. Yet that isn't stopping Toyota from reaffirming its commitment to a segment that has seen its former champions - Ford, General Motors and Chrysler - abandon it with alarming speed. Ford and GM still offer body-on frame utilities, but only in the very largest offerings, catering to seven or even eight passengers. Everything outside of the Expedition or Tahoe rides now on a unibody.
Toyota's decision to stick with the technology is good news if you're in the market for smaller SUVs that are still capable of heading well off the beaten path. Outside of the Jeep Wrangler, Grand Cherokee (a unibody) and perhaps Nissan Xterra, there's not much in terms of capable SUVs between $20,000 and $50,000. As the Toyota brand's US head, Bill Fay, says, "Clearly, the trend has shifted, but there is still an owner base that is interested in these vehicles."
We don't doubt Fay on that, but it may also be somewhat telling that Toyota's SUV lineup is aging, and we haven't seen or heard much about replacement models in the pipeline. Admittedly, the 4Runner (pictured) has been facelifted for 2014, but it's mostly cosmetic in nature. Despite Toyota's posturing, we still expect its body-on-frame lineup to thin in the coming years as sales dwindle and escalating fuel-economy standards make business cases even tougher. Here's hoping that Toyota manages to keep at least one rough-and-tumble SUV in its lineup in the coming years.

Unifor may establish local union for Toyota's Canadian plants

Union tactics apparently translate across borders, as Canada's Unifor may take inspiration from the United Auto Workers' recent move at the Volkswagen factory in Chattanooga, TN, and establish a local for the Toyota factories in Cambridge and Woodstock.
Unifor last attempted to organize the workers at the two factories, which are responsible for production of the Toyota Corolla (above), RAV4 and Lexus RX back in April, but that vote was eventually delayed. According to that report, 3,000 of the two plants' 7,500 employees signed union cards, but that apparently wasn't enough for Unifor to force a vote.
Because of this, the union is looking at the local approach, like what the UAW is attempting with VW.