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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 wants you to meet an 'obsessed' hydrogen fuel cell engineer

Like a television-broadcasting company covering the Olympics, Toyota is looking to market its future in hydrogen fuel-cell vehicle production by taking the personal approach. In this case, the Japanese automaker is telling the backstory of Jackie Birdsall, an engineer at Toyota Technical Center who Toyota says is "obsessed" with fuel-cell technology. A Sacramento native, Birdsall is responsible for testing fuel-cell vehicles and making sure hydrogen stations fill the tanks of the cars in a "reasonable" timeframe. Long a gearhead, she attended Flint, MI's Kettering University (formerly General Motors Institute) and, among other places, worked for the California Fuel Cell Partnership before joining Toyota in 2012. Her first car was an '87 Camry. That's one personal side of Toyota's hydrogen push, and shows another way Toyota is introducing the world to this new powertrain (see also: winter performance). The nitty-gritty is made up of things like working with FirstElement Fuel Inc. on a hydrogen-refueling network in California. As for its fuel-cell sedan, which was displayed in FCV prototype form at the Consumer Electronics Show in Las Vegas in January and is due next year, Toyota said it expects the car to have a full-tank range of about 300 miles and a five-minute refueling time. That's if Ms. Birdsall has anything to say about it. Check out Toyota's press release about Birdsall below. Talkin' 'Bout a Revolution A healthy obsession leads Jackie Birdsall and TTC to the forefront of history The word she keeps using is "obsessed." Jackie Birdsall became "obsessed" with cars when she was a teenager. That made her "obsessed" with the history of auto icons like Henry Ford and Lee Iacocca. In 2003, she did an internship with Daimler-Chrysler, leading to an "obsession" with hydrogen fuel cell technology. And now, as an engineer at Toyota Technical Center, Birdsall is "obsessed" with bringing fuel cell technology to the masses. But perhaps you need to be obsessed when you're trying to change the world. After all, revolutions don't blossom from complacency. Leading an alternative fuel revolution is just what Birdsall and her partners on the Fuel Cell Hybrid Vehicle team are doing. Collectively, they're finding tangible ways to reduce fossil fuels in the automobile world and figuring out how hydrogen fuel cells can be useful and affordable. In 2015, that obsession will bear fruit when Toyota's FCV hits the markets in California, Japan and Europe.

Autoblog Podcast #317

Mitsubishi Mirage, Toyota thinks of beefing up US production, Marchionne on Alfa, Dart and minivans, Ford Atlas concept, Honda Gear concept
Episode #317 of the Autoblog Podcast is here, and this week, Dan Roth, Jeff Ross and Michael Harley bookend the other podcast topics with a pair from the Montreal Auto Show, the Mitsubishi Mirage and Honda Gear concept, and in between we talk about Toyota building all its US-market cars stateside, Hyundai building a Nurburgring test facility, Sergio Marchionne's latest words about Alfa Romeo, Dodge Dart powertrains and the future of Chrysler vans. Some chatter about the Ford Atlas concept finishes up the meat of the 'cast and then we wrap with your questions. For those of you who hung with us live on our UStream channel, thanks for taking the time. Keep reading for our Q&A module for you to scroll through and follow along, too. Thanks for listening!
Autoblog Podcast #317: