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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."

Honda, Subaru airlifting parts to bypass port labor diputes

It should be abundantly obvious that a vital element in building cars is actually having the components on hand to assemble them. A labor dispute on the West Coast between the International Longshore and Warehouse Union and management is not making that quite so easy for some Japanese automakers. Work slowdowns at the ports have pushed Honda and Subaru parent Fuji Heavy Industries into flying some parts into the country. The two automakers began shipping by airplane late last month to avoid production delays, according to Bloomberg, but it has been an expensive solution. Subaru's chief financial officer said the decision cost around $60 million more per month than sending components by cargo ship. They aren't the only companies dealing with the problem, either. Toyota reportedly stopped overtime assembly at some of its factories here because of the delays in getting parts, according to Bloomberg. The dockworkers have been negotiating on a new contract since May 2014, and the current offer on the table to them has offered a 3 percent raise, according to Bloomberg. Although, the union is reportedly considering another slowdown at 29 ports along the West Coast in the coming days. News Source: BloombergImage Credit: Nick Ut / AP Photo Auto News UAW/Unions Honda Subaru Toyota shipping port labor dispute

Recharge Wrap-up: Ford Fusion and Toyota Highlander named Best Hybrids for Families; Funky Prius motorhome

Tesla Model S customers in China will receive a "Universal Mobile Charger" with their vehicle. The charger will allow drivers to charge their Tesla anywhere, without having to search out a Supercharger when out in the wild. It allows Model S drivers a bit more freedom and helps alleviate worries about traveling too far from home. It could also help sway potential customers who suffer from range anxiety. The charger will be free to new and existing customers when it becomes available this summer. Read more at Car News China. US News & World Reports' list of Best Cars for Families includes two hybrids. The 2015 Ford Fusion Hybrid was chosen as the Best Hybrid Car for Families, while the 2015 Toyota Highlander Hybrid was picked as the Best Hybrid SUV for Families. The Fusion hybrid was chosen for its roomy, comfortable cabin, as well as the MyKey system's features for new drivers. The Highlander Hybrid offers eight seats - good for carpooling - as well as good mileage and a quality infotainment system. Read more at US News & World Reports or at Hybrid Cars. Audi plans to give its electric vehicles looks that differentiate them from the rest of the lineup. "In early 2018, we will launch a battery-powered sports activity vehicle in the large premium segment with a range of more than 500 kilometers," says Audi's head of development, Ulrich Hackenberg. "It will have a new, very attractive design, which we are developing especially for the E-Tron range and for battery-electric vehicles." According to analysts, part of the reason the Toyota Prius was so successful was because it was easy to distinguish from other Toyota models with conventional powertrains. Read more at Automotive News Europe. An Australian man turned his Toyota Prius into a miniature motorhome. James Lawler used mostly scraps to build the tiny house – complete with tin roof, chimney, and stained glass window – for just $150 Australian. It took him about a week to finish. Lawler made use of his creation at the Meredith Music Festival so he didn't have to sleep in a tent. He was, however, fined by police for driving the makeshift motorhome. See pictures and read more at the Herald Sun.