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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's Euro Aygo spied in prototype form

The five-door version of the next-generation Toyota Aygo, a Euro offering cloned by the Peugeot 107 and Citroën C1, has been caught out on the town wearing all black. Facelifted early last year, predictions are that the next version of the city car will be slightly lower and wider than the current car, with improved ergonomics and materials. Based on what little can be seen for now, a new intake and headlight treatment should be on the menu in front, with taillights placed higher on its backside.
A three-door version is expected, but a gasoline-hybrid model is also rumored, along with power and fuel economy improvements to the three-cylinder engine that presently puts out 67 horsepower and 69 pound-feet of torque.
We should see it next year, along with the new Citroën C1 and Peugeot 108.

Retro review of the twin-turbo Toyota Supra you missed in the '90s

The twin-turbo fourth-generation Toyota Supra has slowly built up a reputation as one of the premiere sports coupes of the 1990s. The image was partially helped by its inclusion in the original The Fast and the Furious in 2001, but even before that it was part of the quartet of Japanese performance machines along with the Acura NSX, Mazda RX-7 and Nissan 300ZX Twin-Turbo that defined speed for a generation of enthusiasts. Thanks to Motorweek's Retro Review series, now we get a chance to hear opinions on the Toyota from its original release. Two things strike the viewer in the review. First, it shows what a performance standout the Supra TT is. A run to 60 miles per hour in 5.1 seconds and 14 seconds in the quarter mile is strong against its contemporaries and makes it hardly a slouch today. The second surprising thing is just how flabbergasted the reviewers seem at the coupe. The price is up about $8,000 from the previous year, and MotorWeek isn't entirely impressed with the Toyota's weight saving measures that make the fourth-generation Supra a bit more raw than the last model. The great thing about these retro takes is that there's no nostalgia in the way to cloud the reviewers' judgment. Check out the video to find out how the twin-turbo Supra was received before it became part of the performance pantheon.