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Toyota, Suzuki partner on hybrids, EVs, building cars for each other

NAGOYA, Japan — Toyota and Suzuki on Wednesday said they planned to produce electric vehicles and compact cars for each other to better compete with fast-changing technologies in the global auto industry. The agreement follows an initial R&D tie-up announced by Japan's No. 1 and No. 4 automakers in 2017, and will see more vehicles produced by Suzuki for Toyota, one of the world's biggest carmakers. Although Suzuki is far smaller, it is a dominant force in the fast-growing Indian market. The two automakers have been pooling their strengths. Toyota is a leader in hybrid technology and is investing heavily in automated driving, while Suzuki specializes in affordable compact cars — as many automakers struggle to keep pace with ballooning investment in EVs and self-driving cars. Under the latest agreement, Suzuki will source gasoline hybrid systems for cars it sells worldwide from Toyota, which pioneered hybrid vehicles with the Prius more than 20 years ago, the companies said in a joint statement. In return, Suzuki will produce two compact models for Toyota in India based on its Ciaz and Ertiga models. Further cooperation with Suzuki will help Toyota expand its presence in India, the world's fifth-largest passenger car market where it has struggled to grow sales due to lean demand for its lower-cost models. The deepening partnership between the two automakers will enable cost-conscious Suzuki to tap into Toyota's R&D firepower to develop lower-emission vehicles and self-driving cars — areas which Suzuki has admitted it is struggling to keep up. "We believe that the expansion of our business partnership with Suzuki ... will help give us the competitive edge we will need to survive this once-in-a-century period of profound transformation," Toyota President Akio Toyoda said in a statement. The two automakers will deepen their cooperation in India, where Suzuki's hybrid vehicles will be made using engines and batteries locally produced by Toyota. They will also join forces in Europe, where Toyota will produce electric vehicles based on its RAV4 SUV crossover and Corolla wagon for Suzuki, while Suzuki will supply Toyota with gasoline engines for compact vehicle models sold in the region. Suzuki will also produce its Baleno, Vitara Brezza, Ciaz, and Ertiga models for Toyota which will be rebranded and renamed as Toyota models for the African market.

Toyota recalls 112,500 models for steering, transmission issues

Toyota has announced a voluntary recall of a variety of vehicles built between model years 2012 and 2015. Roughly 110,000 of the 112,500 vehicles being recalled consist of the gas and hybrid variants of the 2015 Camry and Highlander, as well as the 2014 and 2015 RAV4. The problem, this time around, is down to a circuit board that may have been damaged during manufacturing of the electric power steering system. According to Toyota, the bad circuit board can lead to a loss of power steering. Owners would still have manual steering control, although they'll have a warning lamp glaring at them from the instrument cluster the entire time. As for the remaining 2,500 vehicles, they're limited to the RAV4 EV, built between 2012 and 2014. A software issue in the electric vehicle traction motor assembly could cause the EV to shift into neutral. As with the issue affecting the Camry, Highlander and gas-powered RAV4, vehicles with this problem will produce a warning lamp in the instrument cluster, as well as a "Check EV" message. Toyota will be notifying owners of the affected vehicles via snail mail, and asking them to report in for free repairs at their local dealership. Check out the whole press release on the issue, available below. TORRANCE, Calif., March 11, 2015 – Toyota Motor Sales, U.S.A., Inc., today announced it will conduct safety recalls of approximately 2,500 Model Year 2012 – 2014 RAV4 EV vehicles; and approximately 110,000 Model Year 2015 Camry, Camry Hybrid, Highlander, Highlander Hybrid, and 2014-2015 Model Year RAV4 vehicles. In the involved RAV4 EV, components in the Electric Vehicle Traction Motor Assembly, which is part of the propulsion system, may cause the vehicle to shift to "neutral" due to a software issue. This condition will also trigger a "Check EV System" warning message on the instrument panel and turn on a malfunction indicator lamp. If the vehicle shifts to "neutral", this will result in a complete loss of drive power, which can increase the risk of a crash. Owners of the involved vehicles will receive a notification by first class mail. Toyota dealers will repair the electric vehicle traction motor assembly. In the involved Camry, Camry Hybrid, Highlander, Highlander Hybrid and RAV 4 vehicles, a circuit board for the electric power steering (EPS) may have been damaged during its manufacturing process. This can result in the loss of power steering assist; an instrument panel warning lamp will also come on.

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."