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Construction of Lexus' first US assembly line underway

The ES is Lexus' top-selling sedan, but the Japanese luxury marque has never manufactured it outside of Japan. In fact, Lexus has never made any cars in the United States, one of its largest markets worldwide. But that's about to change.
Yesterday, construction began in Georgetown, Kentucky, on the first Lexus assembly line in America, the first concrete (or steel) step in a $360-million expansion of Toyota's plant in the Bluegrass state that will create 750 new jobs. The expansion was announced last April by chief executive Akio Toyoda at the New York Auto Show.
Once the new assembly line gets online in the fall of next year, Toyota plans on building some 50,000 units of the ES each year. Lexus sold a record 72,581 examples of the ES in the United States last year - 30 percent more than the previous year - so Lexus will either have to import some more from overseas or leave some buyers disappointed.

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."

Recharge Wrap-up: Honda Grace hybrid goes on sale in Japan, Daimler spends 100M euros on batteries

The Mercedes-Benz S-500 Plug-In Hybrid has earned an Environmental Certificate from the TUV Sud technical inspection authority. The award is based on a lifecycle assessment of the vehicle. This includes the ability to reduce CO2 emissions by 43 percent through charging, and by 56 percent if charged using hydroelectricity. Read more in the press release below. Daimler is expanding its production capacity for lithium-ion batteries. The company is investing around 100 million euros in its subsidiary Deutsche ACCUmotive, who will provide batteries for the electric Smart Fortwo and Forfour, as well as various Mercedes-Benz models. By the end of the construction, Deutsche ACCUmotive will have quadrupled production and logistics space since 2011. Read more in the press release below. Honda has begun sales of its Grace hybrid sedan in Japan. The Grace is based on the Honda Fit and uses the automaker's Sport Hybrid i-DCD system. It comes in front- and four-wheel-drive versions and uses a seven-speed DCT with built-in motor. The Honda Grace starts at the equivalent of about $16,500. Read more in the press release below. Honda has begun operation of its wind farm in Brazil. The farm consists of nine wind turbines, expected to produce about 95,000 MWh of electricity per year, which is on par with Honda's consumption for automobile production in the country. Honda is aiming to cut its CO2 production by 30 percent by 2020 compared to 2000 levels. Read more in the press release below. Toyota has won the 2014 World Endurance Championship's Driver and Manufacturer categories with hybrid technology. Toyota celebrated the win after the final race in Sao Paolo, Brazil. Toyota uses the same hybrid technology in its racing cars as it does in its production vehicles. Read more in the press release below. Controlled Power Technologies and other groups are calling for an international 48-volt electrical standard for vehicles. The groups called for the standard at the International Conference Automotive 48 V Power Supply Systems, saying that the 48V standard for mild hybrids would help make the systems more affordable. This will make it easier for automakers to meet the more stringent CO2 standards anticipated in coming years along with the introduction of the World Light vehicles Test Procedures. Read more at Green Car Congress. The world's first certified three-litre luxury saloon: S 500 PLUG-IN HYBRID receives Environmental Certificate Stuttgart.