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119K Toyota Avalon sedans recalled over airbag woes

Toyota has issued a voluntary safety recall for 119,000 2003-2004 Avalon models because in some cases the airbags could inadvertently deploy.
The automaker says that circuits within the airbag control module could be damaged by electrical noise, which could cause the front airbags and seatbelt pre-tensioners to activate. Dealers are going to repair cars by adding an electrical noise filter to the module. Owners will be notified by first class mail.
Toyota Public Affairs Manager Cindy Knight told Autoblog that there was one reported injury caused by the sudden deployment, but there have been no accidents or crashes. The company is currently preparing the parts for dealers now, and the component takes 90 minutes to two hours to install. "We don't believe there are any other affected models," said Knight.

Mazda rotary engine returning, in an autonomous Toyota delivery vehicle

With the return of the Toyota Supra, the Lotus Esprit and Mazda RX-7 probably share the trophy for hardcore sports cars we'd most like sequels for. The Esprit's too hopeless to consider. Mazda continues to speak in riddles about a new RX-7, but the company has confirmed that the RX-7's heart will return: The company's building a rotary-engined range-extender engine for an autonomous Toyota. At this year's Consumer Electronics Show, Toyota announced its e-Palette autonomous electric delivery vehicle. The e-Palette will come in bus, shuttle, and car versions to service the delivery needs of companies like Amazon, Pizza Hut, and Uber. They'll also be built in custom configurations such as mobile hotel rooms and emergency command centers. Toyota owns 5.25 percent of Mazda, the two automakers recently signed a deal to open a factory in Alabama, and Mazda's known for ace work with small engines. It's not surprising that Toyota chose Mazda for help with the e-Palette, but the rotary aspect is novel. Mazda U.S. president Masahiro Moro said, "This is a very suitable engine to run a generator because it's compact and lightweight, with no noise or vibration, and it has very good fuel economy." There have been rumors of this development previously, as far back as 2016, then again last October in reference to an electric architecture Mazda intended for release in 2019, but Toyota was never mentioned. As to pining for that RX-7 redux, Mazda's head of powertrain said the company's overcome the technical issues of a sports-car-sized rotary engine — the challenge is making a business case for such a sports car. We think the RX-VISION made the case three years ago, and it's already fitted with the Skyactiv-R rotary. Separately, a Toyota spokesman added that the two companies are looking into whether the rotary can be useful beyond the electric car. That's not much to go on when it comes to pining for another RX-7, but hope lives on a scanty diet. Related Video:

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."