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Aging Prius, dropping gas prices putting hurt on hybrid, EV sales

"As Prius represents by far the biggest chunk of the hybrid marketplace, where Prius goes, the segment goes," - Ed Kim, Autopacific
Fuel prices in the US have been tumbling for the last several weeks, with the average price of a gallon of gas at $3.120 as of October 20, according to the US Energy Information Administration. That price reflects a serious recent drop from $3.299 on October 6. Reports have even suggested that those low numbers might not change for a little while, perhaps as long as years. While drivers certainly love paying less at the pump, the change may be hurting the market for more fuel-efficient models, including the Toyota Prius.

Toyota Prius line may not reach 2013 sales target

2012 was a good year for the Toyota Prius line, the hybrid that started it all moving 236,659 units, being the best-selling model in California for the year and the Prius C (pictured) being deemed the most reliable car of 2012 by Consumer Reports. Then 2013 happened, and gas prices dropped more than expected, and people haven't been buying the little hybrids like they used to.
A report in Bloomberg says Toyota set 250,000 units as the Prius family's sales target for this year, but hits like the double-digit drop in year-on-year performance in February have helped lower 2013 sales by 8.4 percent compared to 2012, making the objective "a challenge" to reach. The declines in Prius sales come even as hybrid sales overall were up in the first couple of months this year, including sales of other Toyota and Lexus hybrids. Jim Lentz, Toyota's North American chief, said the Prius target would be adjusted if necessary.

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."