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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."

Jonas wreaks havoc on auto industry

Many folks along the East Coast are still stuck at home from Winter Storm Jonas' brutal snowfall over the weekend, but the blizzard had some nasty temporary effects on the auto industry, too. Winter weather emergencies kept people from leaving the house, and that spelled trouble for factories and dealers. The terrible conditions in Washington, DC, even prevented the the Washington Auto Show from opening. General Motors, Toyota, and BMW had to close factories due to the weather. BMW cited concerns for its workers driving to the plant for canceling some Friday and Saturday shifts in Spartanburg, SC, according to Automotive News. Toyota closed its Georgetown, KY, factory on Friday, and GM shut down the second shift at its Bowling Green, KY, site for that day, too. Showrooms in the blizzard's path saw a massive drop in sales over the weekend because the customers weren't coming. Some affected dealers are now trying to make the best of a bad situation by offering potential buyers even deeper discounts to get them through the door, according to Automotive News. The piles of snow also mean hours of work for employees to clean off all the cars on the lot. The good news is that none of these issues should pose longterm problems. Weather reports don't show much snow for the East Coast in the coming days, which should allow the industry quickly to return to normal.

Airbag recall adds 85k Pontiac Vibes to tally

The repairs needed for the faulty airbag inflators supplied by Takata continue to expand. Toyota initially announced a recall of 766,300 vehicles equipped with the bad part on June 11 as a followup to a campaign from 2013. Soon after, the National Highway Traffic Safety Administration opened a preliminary evaluation into five automakers who also used the component in their models. Now, NHTSA has released the official announcement of the latest Toyota recall listing 844,277 affected cars, including the newly added 2003-2004 Pontiac Vibe.
While NHTSA's document didn't include a model-by-model breakdown, General Motors spokesperson Alan Adler estimated to Autoblog that roughly 85,000 Vibes in the US would be covered under the latest recall. Like the rest of the affected models, the airbag inflator could rupture in a crash causing the bag not to work correctly, possibly spraying metal fragments at the occupant.
Toyota spokesperson Cindy Knight told Autoblog that the reason for the disparity between the earlier press release and NHTSA document was that Toyota was continuing to comb through VINs to create a list of affected vehicles. The original number was an estimate of that process at the time. Scroll down to the recall report from NHTSA.