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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."

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Does Scion's LA concept presage a US Auris?

When the doors open at the LA Auto Show in a few weeks, Scion will be on hand to showcase its new iM Concept. But considering what little Toyota's youthful brand has revealed about the concept so far, it's led to rampant speculation. And the prevailing wisdom seems to point towards a production iM arriving as a Scion-badged version of the Toyota Auris.
For those unfamiliar, the Auris is to European (and other) markets essentially what the Matrix is (was?) to ours: a hatchback version of the Corolla. The model line was first introduced in 2006, looking in its first iteration like an overgrown version of the contemporary second-gen Yaris, and was replaced with the current model in 2012. It's available as a five-door hatch or wagon, with a range of gasoline, diesel and hybrid powertrains available.
If the rumors - spurred by the similarity of the iM concept's nose depicted in the teasers - prove accurate, and public reception to the idea ends up spurring Toyota to put it into action, it wouldn't be the first overseas Toyota brought over as a Scion. The Scion iQ was sold as the Toyota iQ overseas years before it arrived here.