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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."

The techie choice | 2017 Toyota Prius Prime Quick Spin

The Prius nameplate has been inexorably tied to the green car scene for a long time now. When Toyota unleashed the Prius Prime upon the world, we said it was the best Prius yet. But this is no longer a world where Toyota's hybrids are automatically crowned king. Our recent time with the Hyundai Ioniq trio was a stark reminder that the economical, eco-conscious competition is getting stiffer. We put some miles on a Prius Prime to see how our recent Ioniq Plug-In Hybrid test colors our view of Toyota's prime contender. Our first impression: the Prius design is very clean and inorganic. As sterile as it feels, the design appears to have a lot of actual thought behind it. Our Advanced trim tester is spiritually in touch with the mobile gadget culture, with a huge touchscreen, digitization of seemingly everything, and white and black glossy plastic aesthetic. It's a tech-heavy design that will likely seem familiar to those of us who have been interfacing with Apple designs for the past 10 or so years. The Ioniq Plug-In Hybrid, on the other hand, remains truer to the look and feel most drivers expect from their commuters. It's less about user interface, modes, and drive data, and more about just getting behind the wheel and driving. The Ioniq Plug-In Hybrid hardly even distinguishes itself from its plugless counterparts, opting to go green under cover rather than the in-your-face futurism the Prius projects. It retains the traditional instrument cluster in front of the driver, too, which the Prius Prime lacks. In the Toyota, you'll have to look around the car for the right display with the information you're looking for – there's the huge central touchscreen with all its menus, as well as smaller displays above it on the dash – or you can find your speed on the HUD. The Prius is composed in its handling, but doesn't provide much of the sensory feedback that makes one feel connected to the chassis. The steering feels super artificial, but the car stays fairly flat in the corners without providing too much feedback through the seat of your pants. Hyundai's offering, though, proved to be a surprisingly willing dance partner in the corners. While feeling equally as capable as the Prius, the Ioniq's sense of connection through steering and suspension made the act of stitching one turn after another together enough to get our blood pumping. Sport mode makes the Prius Prime slightly livelier, though.

Toyota hydrogen vehicle visits CES, on sale in US in 2015

If there was ever any doubt that Toyota loves hydrogen vehicles, just listen to some of what Bob Carter, senior vice president of automotive operations for Toyota Motor Sales, USA, said today at the Consumer Electronics Show (CES) in Las Vegas: "Fuel cell electric vehicles will be in our future sooner than many people believe, and in much greater numbers than anyone expected." "Hydrogen works beautifully with oxygen to create water and electricity and nothing more." "This [hydrogen] infrastructure thing is going to happen." "I believe what I'm going to tell you about today is going to change our world." Sounds like love is in the air. In all seriousness, Toyota is incredibly bullish on the future of hydrogen as a part of the automotive landscape, and is now gearing up for the 2015 launch of its hydrogen sedan. The concept version of the car was shown for the first time at the Tokyo Motor Show last fall and is making its North American debut at CES today, alongside the still-under-camo engineering prototype. The reasons for Toyota's hydrogen confidence? The debut vehicle is supposed to be a "reasonably priced" car that has a range of 300 miles and a refueling time of about five minutes. Carter highlighted the engineering work that Toyota has done over the past decades to get the fuel cell system downsized while upping power output to over 100 kW. He also said the vehicle will have carry enough energy to power a house for a week, so company engineers are working on an export power supply device. The H2 Toyota sedan will start sales in California (the only state in the US where there are currently any hydrogen stations) next year. The automaker is working with the University of California Irvine's Advanced Power and Energy Program (APEP) to figure out where to build the next series of public hydrogen fueling stations. Today there are ten, but the model Toyota is using "is based on the assumption that owners want to reach a refueling station within 6-minutes" and shows that 68 stations would be able to serve around 10,000 hydrogen vehicles. 'Toyota Car of the Future' On Sale Next Year; Opens 2014 Consumer Electronics Show (CES) Reasonably priced hydrogen fuel cell electric targets 300-mile range, 3-5 minute fill-up LAS VEGAS (Jan. 06, 2014) – "We aren't trying to re-invent the wheel; just everything necessary to make them turn," said Bob Carter, senior vice president of automotive operations for Toyota Motor Sales (TMS), U.S.A.