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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."

Next Toyota Prius coming in 60-mpg 'Eco Grade' version?

There's some mystery surrounding the fuel economy level of the next-generation Toyota Prius. The closest we've had to an official number is 55 miles per gallon, which was hinted at by Toyota Motor Corporation's managing officer, Satoshi Ogiso, last year. That number wasn't an official target, but the company even provided a graphic (above) showing how each next generation Prius beat the previous one by four or five mpg. Since the current, third-gen model gets 50, well, we have been left to guess that 55 is the next logical target. But, according to a new report in Automotive News, the new, fourth-generation Prius that's due next year will come in two versions, with one having a bigger ego – sorry, eco – than the other. AN says that the model will arrive with a standard nickel-metal hydride battery pack in a version that gets "about 55 mpg" and then a new "eco grade" version with a li-ion battery that "will be rated at more than 60 mpg." AN says this information came from company executives who were speaking at an August meeting with Toyota dealers. Our sources within Toyota say that they haven't heard anything about two high-efficiency models, so we'll take this with the requisite grain of salt. The current version of the Prius Plug-In Hybrid does use lithium-ion batteries, but this is the non-plug model the dealers are talking about. We think. The dual-battery strategy is certainly a rumor we've heard before. We had thought that the li-ion pack would be for an extended EV range (the current Prius has a barely noticeable EV-only range), but such a pack would be lighter and could boost efficiency, too. In other words, we look forward to hearing more during the upcoming auto show season.

Toyota outpaces Detroit rivals in profitability per vehicle

As the world's highest volume automaker in 2014, you would probably expect Toyota to project a healthy financial outlook for the end of its fiscal year on March 31. But thanks in large part to the weak value of the yen and a large number of export vehicles, the automaker could make about four times more than General Motors, despite selling just a few hundred thousand more cars than its Detroit competitor last year. Toyota forecasts the equivalent of $24.5 billion in earnings for the fiscal year, compared to $6.5 billion from GM in 2014. According to an analysis by The Detroit News, the Japanese automaker is expecting average earnings of $2,726 on each vehicle it sells, versus $994 from Ford and $654 from GM. The key to this massive success has less to do with Toyota's products and much more in the company's location. The yen's value to the dollar is at its lowest point in decades. Also, according to The News, the automaker exports about 45 percent of its Japan-assembled vehicles, meaning bigger profits in the conversion to foreign currencies. Coupled with strong demand in the US, and the business looks even better. Automakers in the US are peeved by Toyota's currency-based boost. According to The News, there are allegations of manipulation of the yen's value, and Ford president of the Americas Joe Hinrichs calls the problem the "major trade barrier of the 21st century." He thinks the Japanese companies are making about $2,000 per exported vehicle due to the conversion. Intriguingly, it wasn't that long ago when Japanese automakers were moving operations from the country due to the strong value of the yen to the dollar curtailing profits. Infiniti shifted production, and there were fears that Toyota might close some of its factories, as well. Related Video: News Source: The Detroit NewsImage Credit: Shizuo Kambayashim / AP Photo Earnings/Financials Plants/Manufacturing Toyota toyota earnings toyota profit