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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."

Scion rules out roadster, turbo versions of FR-S

Ever since Toyota and Subaru released the sports car alternatively known as the GT86, 86, BRZ and Scion FR-S a couple of years ago, rumors have circulated that even more exciting variants could be in store. But at least as far as Scion is concerned, those rumors are apparently nothing more than wishful thinking. Speaking with WardsAuto at the LA Auto Show last week, Scion chief Doug Murtha said that the prospect of an FR-S roadster has been taken off the table entirely. Apparently Scion lobbied parent company Toyota to produce just such a model, but after failing to find other markets interested enough in the model to put it into production, corporate HQ said no. "I think we were pretty aggressive on our (submitted plan), but we looked at what we would have conceivably lost on the product and said, 'We're not going to even push it further,'" Murtha said, going on to note, "Nobody was more disappointed than we were." Murtha further shot down the idea of a turbo version of the FR-S, dismissing it as a prospect the blogosphere (that's us) wanted to happen but "that's not something that's coming." Either variant might have helped Scion and Toyota boost sales of the model (which are predictably dropping after their first two years on the market), but the investment also might not have paid off their development, tooling and marketing costs. Of course, Murtha can only speak for Toyota, but we'd be surprised to see Subaru go it alone on either model, as costs would be that much more prohibitive without a partner. Bummer.

Toyota unveils two new small displacement engines

Toyota introduced a pair of brand-new engines in Japan today, that it says will eventually spawn 14 different variants by 2015. Where these two engines stand out in today's world, is that neither mill boasts direct injection, and both are naturally aspirated.
The larger of the two is a 1.3-liter, while the smaller engine, a 1.0-liter, was developed in collaboration with Daihatsu. What makes these two unique is that they both use the Atkinson cycle. Now, we aren't going to bore you by explaining just what this is - there's Google for that. Suffice it to say, Atkinson engines are highly efficient, but that efficiency comes by sacrificing power. That's why they're so popular in hybrids, which can offset the power losses.
This focus on fuel efficiency extends throughout the new engines, which also benefit from tweaks like a cooled exhaust gas recirculation system and a trick intake port, while the 1.3 employs Toyota's iE variant of variable valve timing. Both engines can be fitted with stop-start tech. According to Toyota, when fitted with stop-start the 1.3 should provide around a 15-percent bump while the 1.0-liter will increase economy around 30 percent, when they arrive on the road.