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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 Sienna vs Chrysler Pacifica Hybrid | Minivan comparison test

Shopping for a new car can be difficult due to the sheer number of choices. Which brand do you start with, which do you skip and are you missing something worthwhile? Thankfully, minivans are much simpler. There are effectively only four choices, they're all pretty good and they're even different enough to make choosing the right one for you a bit easier. This comparison features the two most recently updated minivans: the Toyota Sienna versus the Chrysler Pacifica Hybrid. Besides their common newness, they stand out in another fundamental way: they're both hybrids. Now, they're very different hybrids – the Toyota comes standard with a traditional gasoline-electric system like that of a Prius, whereas the Pacifica is offered with an optional plug-in hybrid system that provides an estimated 32 miles of all-electric range before effectively turning into a traditional hybrid – but in both cases, fuel economy is the priority. With the rare exception, the minivan segment has exclusively used V6 engines, which provide sufficient power to move hefty loads of people and stuff. The Chrysler Pacifica comes standard with a V6, while a V6 is the sole powertrain option for the Honda Odyssey and new 2022 Kia Carnival. The fuel economy difference between those and our hybrid competitors is staggering: The new Sienna gets an EPA-estimated 36 mpg combined while the Odyssey and V6 Pacifica get 22 mpg. That equates to saving an estimated $750 every year on gas, according to the EPA. And the Pacifica Hybrid could potentially save you even more as long as you routinely utilize its electric range. This frugality alone could send the Sienna and Pacifica Hybrid to the top of many shopping lists, but as we've seen in previous tests, they offer more than enough in other respects to warrant top consideration. But which is better, Sienna or Pacifica? Well, we knew this was going to be close, and we were right. After averaging the scores from 16 categories, the difference between first and second was a mere 0.06 out of 10. When we added extra weight to key minivan-buying attributes (second-row space/versatility, safety features and functionality, infotainment, interior storage, cargo space/versatility, value and fuel economy), the gap was only 1 point out of a possible 230. We then triple checked and conducted a recount, but the order remained. In the end, there are no losers here.

Ford F-150 could be affected by tornado-damaged supplier in S.C.

The disruption caused by a tornado that severely damaged a South Carolina auto-parts plant and killed a contract security guard last week could be felt by more automakers than just Ford and affect more than just its best-selling F-Series pickup, which is due for an update. And there’s still no estimate for when operations might resume at the plant. The Detroit Free Press reports that the BorgWarner plant in Seneca, near Greenville, makes transfer cases for F-150 and Super Duty pickups, the Ford Explorer and Expedition, Transit cargo vans, and Lincoln Navigator and Aviator SUVs. ItÂ’s also a supplier for the Ram 1500 and Toyota Tundra trucks. Transfer cases shift power from the transmission to the front and rear axles in four-wheel-drive vehicles. BorgWarner says it still has no update for when it might partially or fully resume operations. The tornado that ripped through the area in the western part of the state on April 13 tore the roof, walls and signage off the factory and killed a 77-year-old contract worker when the security building he was sheltering in collapsed. Only four or five others were inside the plant, which has been idled because of the coronavirus outbreak, when the tornado struck. In an SEC filing on Friday, Ford said it has sent employees to the site to help BorgWarner and assess the damage to FordÂ’s tooling. “Initial assessments indicate that the Ford tooling was not materially damaged in this incident,” Ford said in the filing. “We do not have sufficient information to estimate when the facility will be back on-line or whether or the extent to which this incident will impact our plans to resume production of four-wheel drive and all-wheel drive vehicles.” A Fiat Chrysler spokeswoman also told the Freep the company was working with BorgWarner on recovery plans. A Toyota spokesman told Autoblog that "we are collaborating with BorgWarner to help restore production for transfer cases for Tundra assembly. We are confident that theyÂ’ll fully recover over time." Like other automakers, Ford shut down production at its U.S. plants last month as a precaution against the coronavirus pandemic. But Ford hasnÂ’t yet said when it plans to reopen its factories. FCA is targeting May 4 to resume production. Models like the F-150 and Lincoln Navigator are major sources of profit for Ford, which estimated it lost $2 billion in the first quarter.