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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 pimps out Esquire van for Japanese businessmen [w/video]

A few months back we reported on a dealership owner in Japan who was petitioning Toyota to make a luxury van. The problem, he reasoned, was that he couldn't take as many friends, colleagues and clients around with him in his Lexus LS, and his Toyota Alphard van wasn't luxurious enough. Well, it seems like he wasn't alone, and Toyota has listened.
The Japanese auto giant has just revealed the Esquire, a new luxury van designed with just such customers in mind. It's significantly smaller than the Sienna we get in America, smaller than the aforementioned Alphard and about the same size as (this writer's favorite) the JDM Noah van (on which we gather it's based). But what sets the Esquire apart is its upscale appearance.
The boxy van is distinguished by its dominant T-shaped chrome grille with a unique emblem that encompasses a shield, sword, "the collar of a gentleman's suit" and the letters Esq. The flank is characterized by a strong beltline with chrome lower window frame and an expansive greenhouse with tinted rear glass. Inside the flexible cabin you'll find accommodation for seven or eight passengers (depending on specification), synthetic leather upholstery and wood and metallic trim. There are even wheelchair-enabled models on offer as well.

Toyota unveils two new small displacement engines

Toyota introduced a pair of brand-new engines in Japan today, that it says will eventually spawn 14 different variants by 2015. Where these two engines stand out in today's world, is that neither mill boasts direct injection, and both are naturally aspirated.
The larger of the two is a 1.3-liter, while the smaller engine, a 1.0-liter, was developed in collaboration with Daihatsu. What makes these two unique is that they both use the Atkinson cycle. Now, we aren't going to bore you by explaining just what this is - there's Google for that. Suffice it to say, Atkinson engines are highly efficient, but that efficiency comes by sacrificing power. That's why they're so popular in hybrids, which can offset the power losses.
This focus on fuel efficiency extends throughout the new engines, which also benefit from tweaks like a cooled exhaust gas recirculation system and a trick intake port, while the 1.3 employs Toyota's iE variant of variable valve timing. Both engines can be fitted with stop-start tech. According to Toyota, when fitted with stop-start the 1.3 should provide around a 15-percent bump while the 1.0-liter will increase economy around 30 percent, when they arrive on the road.