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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."

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We record Autoblog Podcast #317 tonight, and you can drop us your questions and comments regarding the rest of the week's news via our Q&A module below. Subscribe to the Autoblog Podcast in iTunes if you haven't already done so, and if you want to take it all in live, tune in to our UStream (audio only) channel at 10:00 PM Eastern tonight.
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Details about next-gen Toyota Prius emerge

The Toyota Prius is undeniably the king of the hybrid market in the United States, with a 39.4 percent market share in 2013. With the next-generation Prius likely to go on sale in 2015, Toyota is trying to build an even more efficient hybrid to keep its control of the market.
Keeping cost down will be one of the major concerns of the new Prius. The next generation will ride on the new, modular Toyota New Global Architecture platform. The lighter underpinnings will improve efficiency and will reduce production costs by allowing for more shared components among vehicles. Toyota will not reveal how many vehicles will use the new platform. But even with the cheaper platform, price will remain a concern. Toyota is still deciding whether all versions of the next Prius will use lithium-ion batteries or whether some models will stick with the heavier nickel-metal hydride batteries to keep cost down.
Of course, the reason most people buy the Prius is because of its great fuel efficiency. Toyota will aim for at least an 8 percent improvement in fuel economy in the next Prius, which would increase it to 58 miles per gallon city and 52 mpg highway.