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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."

2013 Toyota Avalon Hybrid

People, us included, make a big stink about the importance of family sedans. There's no doubt they're critical - they represent a huge slice of the market's annual sales and profits. However, despite accounting for far fewer transactions than the midsize sedan segment, the fullsize sedan is getting attention from manufacturers now that our market's entire lineup of those (slightly) smaller four-doors has turned over in the last two years or so. As most of the fullsize segment's mainstays derive a fair bit of their platform and powertrain technologies from their midsize cousins, these larger four-doors offer the potential for fatter profit margins, too. And with the newly stylish duds found on many of the industry's most successful midsize sedans, it's only right that automakers no longer think about fullsizers as big, squishy, vanilla family haulers with flat seats, vague steering and a thin layer of 'luxury' in the form of faux wood trim.
As manufacturers have again started diving into large sedans feet-first, the cars themselves have become sharper. The interiors are now of a higher quality and loaded with tech, while the exteriors have become further extensions of each manufacturer's design language. There's perhaps no greater example of this than the Chevrolet Impala and Ford Taurus, two models that evolved from subpar offerings into market leaders. This segment-wide transformation happened quite quickly, whether because of coincidental timing or because manufacturers are trying to get more out of their big cars, recognizing they account for a small portion of overall sales (just 3.5 percent of the new-car market in the first half of 2013).
The 2013 Toyota Avalon Hybrid is one such vehicle. We remarked on the changes to the V6 variant last year, and while we previously had a quick steer of the gas-electric hybrid, we figured the new model was worth a closer week-long look.

Fewest vehicles ever found eligible for Most American survey

Once again, the most American car on the market is from an American brand. The Ford F-150 retained its number one spot in Cars.com's annual survey of the most American vehicles, trumping the Toyota Camry, which remains at number two.
Ford taking the top spot is small consolation, though, as the Detroit Three aren't too well represented here. General Motors scored a win at number seven, with the Chevrolet Corvette, while Chrysler squeaked in at number ten, with the Dodge Viper. Outside of those three vehicles, Toyota and Honda dominate the top ten.
What's most remarkable, though, is that there were so few cars available for this year's list.