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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."

Toyota Recalls 1.9 Million Prius Hybrids

TOKYO (AP) - Toyota is recalling 1.9 million hybrid Prius cars globally for a software glitch that could cause the vehicle to stall. Toyota Motor Corp. said Wednesday that 997,000 Prius cars in Japan, some 713,000 in North America, another 130,000 in Europe and the rest in other regions are being recalled for a problem in the software to control the hybrid system. No accidents or injuries have been reported related to the problem. The software could cause transistors to become damaged, causing warnings lights to go off, driving power to be reduced or the car to stop. The recalled vehicles were manufactured between March 2009 and February 2014. The Japanese automaker suffered massive recalls starting in 2009, affecting more than 14 million vehicles for problems including floor mats, gas pedals and brakes. Affected vehicles include: 2010-2014 Prius vehicles, 2012 Toyota RAV4, 2012-2013 Toyota Tacoma and 2012-2013 Lexus RX 350 vehicles sold in the United States. Related Gallery AOL Autos Test Drive: 2014 Toyota Highlander Recalls Toyota

2014 Toyota Corolla and Tundra production underway

After months of leaked photos and speculative reports, Toyota finally unveiled its 2014 Corolla to the world in early July at a star-studded California party. The confetti has been swept up and the champagne flutes washed and stored, and now the real work can begin: production. Toyota has announced that its new C-segment player has begun rolling off the lines at its plants in Mississippi and Ontario, Canada this week ahead of the planned start of sales in September. What's more, the refreshed 2014 Tundra pickup has also segued into production in San Antonio, Texas.
Corolla production in Mississippi is still a relatively recent phenomenon, with the plant having begun assembly of the outgoing model in the fourth quarter of 2011, while Toyota's Cambridge, Ontario plant has been churning out the compact volume king since 1988. Conversely, the Tundra has been in production at the Texas facility since 2006, and Toyota projects that the plant will build its milestone one-millionth new vehicle in September, right around the time the reworked fullsize pickup goes on sale.