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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."

Lexus gets new boss, and he's a designer

A reshuffle in the uppermost ranks of Lexus could see the Japanese luxury brand further energize its recent focus on design. Tokuo Fukuichi, Toyota's global design boss, is the new head of Lexus International.
Fukuichi will retain his role as the overall head of design for Toyota, Lexus and Scion, and will assume his new position at the head of Lexus and on its board on April 1 (no fooling). This is going to be an interesting move for fans of design to watch, as Fukuichi has repeatedly been mentioned as a designer that enjoys pushing the edge of the envelope and experimenting. He is, after all, the man responsible for designing the most awesomely odd minivan of the 1990s, the mid-engined, rear-drive Toyota Previa, and more recently, he signed off on the controversial Lexus LF-NX concept, which is said to presage a new production small crossover.
"Regarding changes in design, no one has 100 percent confidence," Fukuichi told Forbes back in January 2013. "No one can really say with pure certainty that, 'In two years, this will sell well.'" As Akio Toyoda continues to demand more assertive, edgier designs, it's that point of view that should make Fukuichi a valuable addition to Lexus, as it continues to challenge the competition from Germany.

Toyota mini doc chronicles Tundra towing Space Shuttle Endeavor

Toyota has worked up a quick video detailing the brand's involvement in the transportation of the Space Shuttle Endeavour last year. As you may recollect, the California Science Center ran into a hitch when it came to moving Endeavour from LAX to its new home. While most of the route would be covered by a robotically controlled transporter, one portion of the route directed the shuttle over an interstate. Unfortunately, the bridge across wasn't designed to stand up to the weight of the shuttle and its motorized sled.
The Science Center would have to remove Endeavour from its transporter and place it on a lighter, non-motorized sled. That's where longtime Science Center sponsor Toyota came in. As it turns out, the automaker had to prove to the California Science Center that a Tundra could actually tow the massive shuttle, so engineers put on a little demonstration with a stock truck pulling the equivalent weight over flat ground for the same distance. Once the Science Center was satisfied that the Tundra could pull it off, the move was green lit and the rest is history. Check out the short documentary below for yourself.