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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 plotting WRC-inspired Yaris hot hatch

The emergence of the new Honda Civic Type R goes to show that the Japanese can make hot hatches every bit as good as the Europeans. But though it's been a while since Toyota had a serious contender in the game, word has it that it's about to jump back in. The impetus for Toyota's (re-)entry into the hot hatch segment is its impending return to the World Rally Championship. The company announced just a couple of months ago its intention to run a Yaris-based (or at least -styled) rally machine in the WRC by 2017, and now the latest reports indicate a road-going version won't be too far behind. Though the competition-spec model is expected to pack a 1.6-liter turbo four built by Toyota Motorsport GmbH specifically to comply with FIA regulations, the street-legal Yaris hot hatch is tipped to carry the 2.0-liter turbo four from the Lexus NX 200t. Though the jury's still out, it'd likely stick with front-drive instead of a more complex all-wheel drive system, but with a six-speed manual and a limited slip differential, it has all the potential to be a real firecracker. Only a limited number will likely be offered, ostensibly to meet FIA homologation requirement – in the same vein as the Citroen DS3 Racing or the Volkswagen Polo WRC Street – and likely to carry a similarly premium price tag in the neighborhood of 34,000 euros. We'd be pleasantly surprised if any of them were to make it to North American showrooms, though.

See how Toyota Mirai hydrogen fuel cell car is made [w/videos]

Toyota kicked off production of the Mirai hydrogen fuel cell sedan at its Motomachi factory campus in December, and at the time the company had orders for 200 of them. In just the few months since then, demand has already jumped to requests for at least 1,500 of the potentially revolutionary vehicles. For the first time, the Japanese brand is taking viewers into the innovative model's production process and showing the sedate pace of putting them together. The line used for the Mirai was formerly home to Lexus LFA production. Like that low-volume, cutting-edge supercar, Toyota is prioritizing quality and precision for its fuel cell vehicle. At the moment, it's building just three of the sedans per day with a tight, dedicated team. According to Automotive News, there are just 13 people assembling the cars right now, and at most they could only complete 10 per day. The production process for the Mirai is more akin to a boutique sportscar than the high-volume efficiency Toyota usually shows. There's no belt moving them along, and instead each one is pushed between areas. With so much riding on these models, this approach is meant to guarantee an attention to quality. "These facilities are not so advanced. Rather, we rely on the work of our skilled employees. This is similar to how things were when Toyota was just starting out," said Toyota President Akio Toyoda during a ceremony at the plant, according to Automotive News. Toyota has released a gallery of images and five videos showing the major steps in the Mirai's production process, including the complicated installation of the fuel cell stack. All of the clips are embedded below. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings.