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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."

First Toyota unintended acceleration case headed for trial

Toyota is going to be back in the spotlight, as the first of its unintended acceleration lawsuits is headed for trial. This case covers a Los Angeles sushi shop owner, Noriko Uno. According to the what the family told The Detroit News, Uno only put about 10,000 miles on her 2006 Toyota Camry in four years. Uno was apparently afraid of high speeds, avoiding the freeway and taking a route home along LA's surface streets to avoid them.
On August 28, 2009, Uno's Camry suddenly accelerated to 100 miles per hour, eventually striking a telephone poll and a tree and killing her. The family contends that Uno attempted to step on the brakes and pull the emergency brake, neither of which brought her speed under control, while Toyota maintains that improperly installed floormats and driver error have been behind the majority of the 80 cases expected to be heard in court.
In Uno's case, The Detroit News is expecting the trial to focus on the lack of an override if the gas and brake pedals were pressed at the same time. Brake overrides were installed on Toyota's European fleet. The Uno family attorney will need to prove to the jury that it wasn't driver error that killed Noriko Uno.

Legal approach in $1.2 billion Toyota settlement could impact handling of GM recall cases

In the past, if an automaker did something wrong, they were usually prosecuted by the US government through something called the TREAD Act. Short for Transportation Recall Enhancement, Accountability and Documentation Act, it basically requires automakers to report recalls in other countries, along with any and all serious injuries or deaths, to the National Highway Traffic Safety Administration.
Failing to report or attempting to conceal anything when there's been a death or serious injury constitutes a criminal liability. The idea is that this setup puts the onus on manufacturers to keep NHTSA apprised of safety related issues before they become a problem in the US, thereby allowing the regulator to better protect consumers.
In theory, it sounds like a relatively airtight set of rules for dealing with misbehaving automakers. That didn't stop the US Department of Justice from ignoring TREAD in its prosecution of Toyota's handling of the unintended acceleration recall, though. The result of this new approach, which charged Toyota with wire fraud, was a $1.2 billion settlement. Now, the wire-fraud approach could be used for the expected case between the US government and General Motors, based on the statements of Attorney General Eric Holder, who specifically mentioned "similarly situated companies" when discussing Toyota.