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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 recalls 2016 RAV4, RX350, and ES350 for stability failure

The Basics: Toyota will recall 4,170 examples of the 2016 RAV4, 90 units of the 2016 Lexus RX350, and 12,400 units of the 2016 ES350. The Problem: A component in the brake actuator assembly may have damage from a manufacturing error. The actuator controls the anti-lock brakes, traction control, stability control, and other systems. If the part doesn't work properly these safety systems might not activate properly. Accidents/Injuries: Toyota spokesperson Amanda Rice told Autoblog, "Regarding the recent recalls, alleged crashes, injuries, and fatalities are reported in many ways to many different organizations. We are not providing specifics at this time." The Fix: Dealers will check the brake actuator's serial number and will replace it if the part comes from a period when the damage could have happened. If you own one: Toyota will contact affected owners by mail. Related Video: TOYOTA RECALLS CERTAIN 2016 MODEL YEAR RAV4 AND LEXUS RX AND ES VEHICLES TORRANCE, Calif., April 6, 2016 – Toyota Motor Sales, USA, Inc. today announced that it is recalling approximately 4,170 Model Year 2016 Toyota RAV4; approximately 90 Model Year 2016 RX350; and approximately 12,400 Model Year 2016 ES350. The involved vehicles are equipped with a Brake Actuator assembly that enables enhanced brake control functions including the Anti-lock Braking System (ABS), Traction Control (TRAC), and Vehicle Stability Control (VSC), among others. There is a possibility that a component inside the actuator could have been damaged during manufacturing, preventing the actuator from operating properly. This could cause a loss of vehicle stability control, increasing the risk of crash. All known owners of the affected Toyota vehicles will be notified by first class mail. Toyota and Lexus dealers will check the serial number of the Brake Actuator and replace actuators assembled during a specific production period. Information about automotive recalls, including but not limited to the list of involved vehicles, is subject to change over time. For the most up-do-date Safety Recall information on Toyota, Lexus or Scion vehicles, customers should check their vehicle's status by visiting toyota.com/recall and entering the Vehicle Identification Number (VIN). Safety Recall inquiry by individual VIN is also available at the NHTSA site: safercar.gov/vin.

Akio Toyoda pledges return to WRC in 2017 with a Yaris

There have been rumors of Toyota returning to the World Rally Championship since the end of 2013, and a Yaris prepped by Toyota Motorsport in Germany has been caught on The Continent several times last year in testing. Akio Toyoda visited Rally Finland while we were there with Hyundai to watch a race up close, and he said that the passion people still had for Toyota's past exploits encouraged him. He finally answered the question about when they planned to enter the series, announcing in Tokyo that they'd line up for the season in 2017. The Japanese company, a legend in rallying, got into the sport in 1979 and left in 1999 after winning seven titles in ten years through the nineties with Carlos Sainz and Juha Kankkunen. The 2017 return is likely due to the regulation changes that year to allow more power than the roughly 300-horsepower in today's challengers and the switch to a fuel-flow formula to let manufacturers use different kinds of engines. Toyota has been sitting in on the WRC rules meetings, and the final slate of changes will be announced at the end of this year. The Yaris that's been testing is powered by a 1.6-liter, four-cylinder that meets current regulations, but we can expect it to change somewhat before it's race-ready. TMG will test the car for the next two years, then it will go up against fellow manufacturers Volkswagen, Hyundai, and Citroen, as well as Fords run by M-Sport. There's video of the Yaris running solo through the Belgian countryside above, and a gallery of the coming car below.