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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."

New autonomous testing ground in Michigan will help battle bad weather

If one of the big weaknesses of autonomous vehicles is their ability to navigate in the snow, consider this a trial by fire. The American Center for Mobility says it has opened its $110 million driverless car testing facility on the site of a former General Motors assembly plant in Michigan, with Toyota and auto supplier Visteon the first to begin testing this week. The ACM proving ground is a 500-acre site at historic Willow Run in Ypsilanti Township, near Ann Arbor. It's one of 10 sites designated by the U.S. Department of Transportation as pilot proving ground sites to test AV technologies. It features a variety of simulated environments to test driverless cars, including a 2.5-mile highway loop, two double overpasses, intersections, roundabouts and a 700-foot curved tunnel. It also opens just as the region experiences a series of snowstorms and the first frigid temperatures of the season. That ability to test autonomous vehicles in a wide variety of weather conditions is important, as autonomous vehicle sensors have struggled to handle cold, wet and snowy conditions. Google parent Alphabet in October said its Waymo division was expanding its winter testing operations to Michigan, making it the sixth state where it's testing its driverless car systems. In a Medium blog post, Waymo CEO John Krafcik wrote that "This type of testing will give us the opportunity to assess the way our sensors perform in wet, cold conditions. And it will also build on the advanced driving skills we've developed over the last eight years by teaching our cars how to handle things like skidding on icy, unplowed roads." Waymo also opened a development center in suburban Detroit in 2016, working with Fiat Chrysler to integrate its autonomous technology into Chrysler Pacifica hybrid minivans. Visteon began testing and validating its DriveCore autonomous driving platform to evaluate algorithms, vehicle-to-vehicle and vehicle-to-infrastructure technology and other systems. Toyota used the facility Wednesday to begin orientation and driver training. ACM has so far secured $110 million to construct the first two phases from founders Ford, Hyundai America Technical Center, Toyota and Visteon, and says it expects to announce more investment soon.

Recharge Wrap-up: Mazda, Toyota earn environmental awards

Electric mobility nonprofit Drive Oregon has launched a campaign to invite the electric car industry to perform testing in the state. The campaign tells companies to, "Test Drive the Future in the Living Lab," citing Oregon's density of EV owners and charging infrastructure, varied terrain and climate, funding opportunities, and the state's technological reputation as the "Silicon Forest." Plus, as Drive Oregon Executive Director Jeff Allen, points out, "if you really screw things up here, it doesn't make as much noise as it would in California." Already, Jaguar Land Rover has announced plans for an Innovation Incubator in Oregon. Read more at Green Car Reports. Mazda's new paint system has won the Prime Minister's Award in the category of Manufacturing and Production Process at the 6th Monodzukuri Nippon Grand Award ceremony. Mazda's Aqua-tech paint system significantly reduces emissions of volatile organic compounds (VOCs) and CO2. The Aqua-tech system uses a water-based color basecoat and a urethane clear coat to reduce VOC emissions by 57 percent. It consolidates the painting process and reduces energy in paint-booth air-conditioning and flash-off processes to reduce energy consumption. It also allows Mazda to create such colors as Soul Red, which looks quite nice on the MX-5 Miata. Read more at Green Car Congress, and learn all about the Aqua-tech paint process from Mazda. The Toyota Mirai has received a 2015 Environmental Award from Austrian automobile club ARBO. The hydrogen fuel cell car took the prize in the category of Current Innovative Environmental Technologies. "At Toyota, we believe that various technologies will co-exist, ranging from EVs to hybrids to the most innovative of all, the fuel cell car," says Gerald Killmann, Vice President R&D of Toyota Motor Europe, in a comment thanking ARBO. "Mirai is a core component of Toyota's vision for a sustainable mobility society, one that allows us all to move freely in comfort and safety in an environmentally friendly, sustainable manner." Read more in the press release below. Vienna, Austria- November 5th - The Austrian automobile club ARBO* (Auto-Motor und Radfahrerverbund Osterreiche) has awarded the Toyota Mirai with the "2015 Environmental Award". This Award was received during a gala ceremony held yesterday in Vienna, where the Toyota Mirai was awarded in the category of "Current Innovative Environmental Technologies" . The jury consisted of ARBO automotive experts.