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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."

Production Mazda Vision Coupe concept, GRMN Supra, new BRZ/86 coming

After writing about what's in store for the next-generation Subaru WRX, Japan's Best Car magazine is back with more spy work on what's ahead for the coming Mazda sedan, fighting-spec GRMN Toyota Supra, and next-generation Subaru BRZ/Toyota 86. All three are supposedly headed for previews at this year's Tokyo Motor Show before rolling out in 2021 and 2022. Mazda showed the Vision Coupe concept at the 2017 Tokyo show, then sneaked a mention of a rear- and all-wheel drive "Large Architecture" and two inline-six engines into a 2019 investor's report. Best Car says that concept's production version will house a 3.0-liter Skyactiv-X SPCCI inline-six with "M-Hybrid" 48-volt assistance. Output figures remain a mystery, but the mag says engineers are aiming for 345 horsepower. The real deal isn't slated for dealers until 2022, bringing what Mazda bills as a "BMW, Audi quality car at the price of Volkswagen." A further treat: Best Car says the Hiroshima automaker is laying out a two-door version on the same platform. Not even a month after 2020 Toyota Supra chief engineer Tetsuya Tada told us, "With a sports car, the promise is to offer more performance with each additional version," this report says the full-fat GRMN Supra will raise the stakes. Expected in the latter stages of 2021, the current 335-hp Supra will get an "output eventually close to 400 ps" (about 394 horsepower) from its BMW-source 3.0-liter straight-six. Along with that will come a lighter, stiffer body, and a sportier suspension tune to manage and make the most of the 60-horse increase. Best Car says the next-generation Toyota 86 / Subaru BRZ will move to a new platform, without specifying whether it would be Toyota's TNGA platform suggested by a report in April — not that there are many other options. Neither the footprint nor the body dimensions are predicted to change, and transmissions will continue to include a six-speed manual and a six-speed automatic. The new platform will hold a new engine, although it won't be the revelation many fans want. The magazine says the Subaru 2.0-liter FA20 will retire, making way for the Subaru 2.4-liter FA24. The FA24 is the same engine in the Subaru Ascent crossover, where it produces 260 hp and 277 lb-ft. There'll be no such fireworks for the sporty twins due in the first half of 2021, output reported to be "improved to 220 ps," or 217 hp — a 12-hp bump over the current figure.

Honda Civic overtakes Toyota Corolla as America's best-selling compact

The battle to claim October's best-selling compact sedan title has been won by the Honda Civic. The Japanese four-door sold 27,328 units, leaving the Toyota Corolla - September's title holder - in its wake with 23,637 units sold. In terms of year-to-date sales, the Civic sits at 280,899 units, with the Corolla trailing at 257,184 vehicles.
Sitting in third place, separated by a significant gap from the leaders, is the Chevrolet Cruze with 16,087 units sold. The Ford Focus earned fourth, with 15,108 units moved out of showrooms. (It is interesting to note that while the Civic and Corolla have both enjoyed double-digit sales increases year-over-year, the Cruze and Focus have seen significant decreases during the same period.)
Sales of the Hyundai Elantra hit 14,876 units, putting it in fifth place, with the Volkswagen Jetta earning sixth place with 11,710 units. Rounding out the ten top sellers were the Nissan Sentra (8,399 units), Mazda3 (7,647 units), Dodge Dart (5,617 units) and Subaru Impreza/WRX (4,923 units). The Kia Forte (4,706 units) and Volkswagen Golf (2,249 units), eleventh and twelfth respectively, have fallen behind.