2014 Toyota Avalon Limited on 2040-cars

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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."

Toyota recalling 1.67 million vehicles worldwide in 3 campaigns

Toyota is issuing three separate recalls covering 1.67 million vehicles worldwide with most of those models in Japan. It looks like the campaigns' impact on the US may be smaller, though. According to Reuters, Toyota isn't aware of any accidents, injuries or fatalities affecting the models. Some yet-unnamed Lexus models might also be affected.
The largest of the campaigns does not currently affect any US-market vehicles. About 802,000 units of the Toyota Crown Majesta, Crown, Noah and Voxy in Japan are being repaired to replace a seal that could leak in the brake master cylinder. Those already leaking get a new brake booster, as well, according to Reuters.
The only recall currently believed to affect the US is due to a problem covering approximately 759,000 vehicles with 423,000 of them here. The repair is to fix a faulty fuel delivery pipe that could cause a fire if the fuel leaks out. Unfortunately, we don't know which models it covers. Autoblog spoke to Toyota spokesperson Mona Richard and was told the information was still "under embargo." When exactly that embargo will lift isn't yet known, but we're on the case.

Toyota announces production increase for Mirai fuel cell vehicle

Toyota is building them. People are coming. So Toyota's going to build some more. Cue the strings. The Japanese automaker apparently got more than it bargained for after starting sales of its first mass-produced hydrogen fuel-cell vehicle last month. On Thursday, Toyota announced plans to ramp up production starting next year. Toyota will build 700 Mirai units this year, and will then bump that to 2,000 vehicles next year and 3,000 in 2017. The previous production plan had the same numbers, except for what would happen in 2017. The increase is coming because Toyota's already received pre-orders for 1,500 Mirai vehicles. With US and European sales slated to start later this year, Toyota didn't want to leave itself short-stocked. Toyota confirmed what was already being surmised last month by the Japanese newspaper Nikkei, which said that Toyota was ready to spend almost $170 million boosting production capacity of the Mirai. Most of this year's sales will be in Japan, with the US and Europe gradually accounting for a larger chunk starting next year. In November, the automaker disclosed details of the Mirai's initial US sales, saying that the model will be available in California this year for either a base price of $57,500 or a lease price of $499 a month for 36 months (with $3,649 due at signing). And if that sounds steep, remember that the hydrogen refueling, wherever it can be found, is free for as long as three years. Check out Toyota's press release on the bumps in production below. Toyota to Increase 'Mirai' Production Toyota City, Japan, January 22, 2015-Toyota Motor Corporation today announced that it will increase production of the "Mirai" fuel cell sedan, which launched in Japan on December 15, 2014. The new plan calls for production to increase from the 2015 level of 700 units to approximately 2,000 units in 2016 and approximately 3,000 units in 2017. Considering the approximately 1,500 orders received in the first month of sales in Japan, and the upcoming launches in Europe and the United States later this year, it was decided that the supply structure should be adjusted to reflect the level of demand for the vehicle. Sales plans for Japan, the U.S. and Europe following the production increases will be formulated taking into consideration each region's level of hydrogen infrastructure development, energy policies, car-purchasing subsidies, consumer demand, environmental regulations, and other factors.