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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 pondering high-performance GT86 hybrid?

From what Autocar has to say, Toyota has even more plans for the GT86 beyond the convertible concept we just saw at the Geneva Motor Show. Along with a planned midcycle facelift, Toyota is reportedly looking at how to pack some extra ponies under the coupe's hood, and while there has already been a lot of talk about superchargers and turbochargers, it sounds like a performance-boosting hybrid system could also be in the works.
Talking to Toyota chief engineer Tetsuya Tada, Autocar has learned that the automaker is considering an electrical motor assist for the sporty coupe to improve performance without harming fuel economy. In attempting to keep weight - and, presumably, costs - down, the article mentions the use of a system closer to what Honda uses for its Integrated Motor Assist rather than a full Hybrid Synergy Drive system used in current Toyota hybrids. Tada says the added weight of the system could be offset by weight reduction, while aerodynamic changes and a lower center of gravity could improve the car's handling.
No word yet on whether a mild hybrid system would find its way to North America's Scion FR-S - let alone its Subaru BRZ twin - but the thought is certainly an intriguing one.

Japanese spark plug giant NGK pleads guilty to price fixing, to pay $52M fine

The ongoing investigation by the Department of Justice into price fixing in the automotive industry has nabbed one more company breaking the law. Japanese parts giant NGK Spark Plug Company agreed to plead guilty to a felony count of pricing fixing and bid rigging in the in the US District Court in Detroit. Its punishment is a $52.1 million criminal fine and to continue to cooperate with the DOJ's sleuthing into the problem.
According to the DOJ, NGK conspired to fix prices on spark plugs, standard oxygen sensors, and air fuel ratio sensors on vehicles from major automakers in the US, including the former DaimlerChrysler, Honda and Toyota, in a scheme that ran from at least January 2000 to July 2011. The charge claimed that the company and its co-conspirators held meetings where they agreed on bids and price quotes that were submitted to the automakers.
With the latest plea, the DOJ has caught 28 companies and 26 executives for price-fixing and bid rigging in the auto parts industry, and they have collected $2.4 billion in criminal fines. In 2013, the feds brought nine Japanese suppliers down at once, to collect $740 million. Scroll down to read the DOJ's complete announcement of the case.