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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 investing $200M in Southern manufacturing

Over the past two years, Toyota has invested more than $2 billion at its North American production facilities, and it apparently doesn't plan on stopping there. To keep up with recent strong sales, Toyota is investing an additional $200 million at its engine plants in the Southern US to increase production capacity of its V6 engines.
The bulk of this money ($150 million) will go to expand Toyota's engine plant in Huntsville, AL, which is currently responsible for supplying engines - four-cylinder, V6 and V8 - to eight of Toyota's 12 domestically produced vehicles. That includes the best-selling Toyota Camry (shown above).
Toyota didn't say exactly what improvements are being made to the plant, but this follows last year's $80 million investment in the plant that is set to be completed by next year raising the engine capacity to 750,000 annual units including 362,000 V6s. The remaining $50 million will go to the casting plants of Toyota-owned Bodine Aluminum in Missouri and Tennessee, which supply engine blocks and cylinder heads to the Huntsville engine plant as well as others in Kentucky and West Virginia. Scroll down below for the official press release.

Toyota working on cars that hover above the roadway

Toyota is one of the largest automakers in the world, but it's not content simply building and selling conventional cars - it's been at the forefront of numerous advancements in ground transportation. It is widely credited with advancing the cause of hybrid propulsion, and alongside Audi and Google, is among the first automakers seriously testing self-driving cars. We could go on, but the news here is that Toyota is reportedly developing vehicles that hover above the road surface instead of rolling along it.
The news comes from Hiroyoshi Yoshiki, one of Toyota's tech gurus, who revealed at Bloomberg's Next Big Thing summer in San Francisco that the company is working on hovering cars - ones that travel just above the road surface, but don't actually fly in three-dimension space.
According to The Verge, a spin-off of our own sister-site Engadget, Yoshiki refused to elaborate on what the project entails and how far along it is. He was speaking along acting NHTSA chief David Friedman, who lauded such advancements as a "great taste of innovations to come," but stressed the significance of more concrete improvements to conventional automobiles - like inter-car communications to keep vehicles from colliding on the highway - as more relevant to today's industry.