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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 Europe boss says 'reasonable number' of fuel cell vehicles on the way

We know that Toyota is gung-ho about delivering its first hydrogen fuel cell sedan to early-adopter markets like southern California and part of Japan next year. The Japanese automaker's European H2 plans have long been part of the mix, but a new press release shows just how committed Toyota is to hydrogen all around the world. "The volume will be limited, but they will be visible on the streets" – Didier Leroy Toyota says hydrogen fuel cells are a "major, but logical next step" after the company's pioneering work on gas-electric hybrids for 15 years. Didier Leroy, president of Toyota Motor Europe (pictured), said in a statement that he knows there will be H2 hurdles, and so Toyota will start with "a reasonable number of cars" in Europe. "The volume will be limited," he said, "but they will be visible on the streets." Karl Schlicht, Toyota Motor Europe executive vice president, compares Toyota's current hydrogen progress with where the company was with hybrid's in the not-too-distant past. When it comes to infrastructure and cost, he said, "There is of course a long way to go, as with any game-changing technology, but remember the same was said about hybrid only 10 years ago." You can read the full PR below. We don't remember a lot of people saying the infrastructure for hybrids simply wasn't there in 2004, but maybe we missed that memo. TOYOTA EXECUTIVES SET THE SCENE FOR DELIVERING FUEL CELL TECHNOLOGY 16/04/14 from Toyota The next era in Toyota's technology development is about to become production reality, with the market introduction next year of the company's first hydrogen fuel cell-powered car. It's a major, but logical next step for the company, as it builds on the success it has achieved with hybrid over the past 15 years. Karl Schlicht, Executive Vice President of Toyota Motor Europe, is explicit about Toyota's commitment to hydrogen power and the potential of fuel cell vehicles to deliver on the company's ambitions to develop the ultimate eco-car. He says: "Our unique hybrid history and experience have proven invaluable for the next big leap. Back in 2010, we promised our first fuel cell car for 2015 and we are fully on track to honour our commitment. "Fuel cell is a technology that can secure our concept of personal mobility. That's because fuel cells combine the strengths of EVs (electric vehicles) and hybrids, with those of conventional cars.

Ex-Toyota Bill Reinert still in favor of hybrids, against EVs

Former Toyota executive Bill Reinert is so unsold on electric vehicles as a viable advanced-powertrain option for future transportation that he has praised – gasp – Ford, for its downsized internal combustion engines. Reinert was a key player in developing Toyota's original Prius hybrid and, in an interview published in Yale University's Environment 360 blog, said a hybrid that gets 60 miles per gallon is superior to an electric vehicle. "And that is why you will be seeing more fuel cells in the future." – Bill Reinert Reinert went on to praise the advances that automakers have made in improving fuel economy of fossil fuel vehicles, specifically namechecking Ford and its three-cylinder Ecoboost engine. He also has good things to say about both hydrogen fuel-cell electric technology as well as natural gas vehicles, but admits that limited fueling infrastructure will keep those types of vehicles in the margins for the near future. He also says that hydrogen vehicles aren't that great yet but that, "When most [manufacturers] investigate the two technologies [H2 and EVs], they see that FVCs offer more room for performance improvement and cost reduction potential. And that is why you will be seeing more fuel cells in the future." As far as pure electric, Reinert says lithium-ion batteries have "tremendous shortcomings" and talks about battery degradation, substandard performance in hot weather and, of course, limited single-charge driving range. He also says that people need to factor in the environmental impact of producing electricity for the grid to fully gauge how environmentally beneficial EVs can be. We'd like to take him and Tesla Motors Chief Elon Musk to what we think would be a spirited lunch. You can read the whole interview with Reinert here.