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Toyota to ramp up Tacoma production in Mexico by 41%

The Toyota Tacoma may be getting on in age, but that isn't stopping the Japanese manufacturer from ramping up production at the pickup's Baja California factory. The Mexican plant will soon be home to another 300 jobs as it increases total capacity by 41 percent. The increase is slated for April 2015.
The move is a curious one, considering the Tacoma's age and the fact that General Motors is preparing what, on the surface, appear to be two very competent challengers. The factory increase could be in preparation for the 2016 Taco (spy photos shown above), which is expected to represent a significant overhaul of the long-serving truck.
Toyota's decision to increase capacity could also be due to the factory building freeze implemented by President Akio Toyoda, according to Automotive News. Toyoda put a hold on new factories until 2016, asking executives to squeeze as much production as possible out of remaining factories before bringing any additional facilities online.

Toyota to offer sedan version of GT 86?

Sources in Australia are reporting that we'll be seeing a small, rear-drive sedan from Toyota, based on the GT 86/Scion FR-S. Yes, a convertible variant is still in limbo, but a four-door sedan is in the works. It's unclear if the rumored GT 86 sedan would spawn Scion and Subaru variants (it's hard to cross all ten fingers while you type, but we're having a go).
Working with remarks made by the car's chief engineer Tetsuya Tada in his blog and a rendering from Japanese magazine Holiday Auto, the Australian site Motoring is claiming that the new model's wheelbase will grow about four inches over the current GT 86's 101.2-inch wheelbase.
Besides the larger overall space between the axles, the sedan will offer a more potent engine option over the current 2.0-liter, flat-four. Promising 268 horsepower, which is a big jump over the current car's 200 ponies, the new powertrain will be derived from the Hybrid R setup, shown at the Frankfurt Motor Show. If, like us, you're reaching for the salt, and we don't blame you.

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."