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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."

Porsche takes 2016 Le Mans win on last lap, Ford grabs class victory

So far, only one Japanese manufacturer has won the 24 Hours of Le Mans endurance race. That carmaker was Mazda exactly 25 years ago with the legendary, rotary-engined 787B. This year, Toyota was amazingly close to winning with their TS 050 car, piloted by Kazuki Nakajima, and it all ended in tears on the last lap. The Toyota ran smoothly for almost 24 hours, but to lose power and stall on the pit straight with five minutes to go is nothing short of catastrophic. Still, the #5 car was able to be restarted and limped across the finish line for 45th place. Toyota's #6 car had its own set of issues, as the car gained bodywork damage and also veered off track in the hands of Kamui Kobayashi. Driven to second place, the Toyota #6 passed the finish line driven by Stephane Sarrazin. For Porsche, the win with the #2 919 Hybrid was the 18th constructor title at Le Mans 24 Hours. The car was driven by Romain Dumas, Neel Jani and Marc Lieb, and it proved to be more reliable than the #1 919 with Timo Bernhard, Mark Webber and Brendon Hartley behind the wheel. The #2 Porsche and the #5 Toyota battled for the lead throughout the day. Had the Toyota not broken down, Audi would have missed a podium finish for the first time in 18 years - a great run was ruined this year by turbo trouble in the #7 R18 e-tron Quattro driven by Lotterer-Treluyer-Fassler, and the third place was taken by the #8 Audi with Lucas Di Grassi driving. Winners #LeMans24 #919Hybrid @Porsche_Team @neeljani @LiebMarc @RomainDumas but kudos to @Toyota_Hybrid team pic.twitter.com/TLRuwuSTzx — Porsche GB (@PorscheGB) June 19, 2016 ??? #LeMans24 pic.twitter.com/zUkBbA65RK — Peter Leung (@BaronVonClutch) June 19, 2016 In the GTE Pro Class, Ford had reason to celebrate: the #68 Ford GT campaigned by Chip Ganassi Racing took a class win 50 years after Ford's 1-2-3 GT40 Le Mans win in 1966. 50 years to the day following the '66 Le Mans 1-2-3, the No. 68 #FordGT has won the GTE Pro Class at #LeMans24 pic.twitter.com/jkMLuWlEYm — Ford Performance (@FordPerformance) June 19, 2016 For the full list of official results, click here.

Recharge Wrap-up: 1M Lexus hybrids, Best Buy Geekmobile goes Prius

Cummins is developing a plug-in hybrid system for heavy trucks. Its plug-in system for Class 6 trucks (those with a gross vehicle weight between 19,000 and 26,000 pounds) is expected to improve fuel economy by 50 percent. Funded in part by a $4.5-million grant from the US Department of Energy (DOE), the system will use a battery pack and some form of range extending internal combustion engine. The system will employ various drive cycles in order to help commercial fleets save fuel based on their needs. Read more at Gas2. German automaker Borgward, LG Chem, Bosch, and software firm SAP have joined forces to form an electric mobility partnership. Borgward recently revived its brand with a new model, the BX7. Borgward has also announced that two other models, the BX5 and BX6, will be available as plug-in hybrids. SAP will provide software services, and LG Chem will supply battery technology to Borgward. Bosch will supply and help develop a number of components for Borgward cars. Read more at Inside EVs. Lexus has sold its millionth hybrid. The luxury automaker began selling hybrids with the electrified RX in 2005, and the millionth hybrid was a NX 300h sold to a customer in Milan, Italy. "This is my first Lexus," says the customer of that vehicle in a Lexus release, Aldo Pirronello. "... and I am honored to celebrate this important milestone with Lexus!" Lexus currently sells 10 hybrid models worldwide. Read more from Lexus. Best Buy's Geek Squad is switching from Volkswagen Beetle Geekmobiles to the Toyota Prius C. As part of an update to the home electronics chain's house call service, the Geeks will be driving more eco-friendly cars with a refreshed logo. More than 1,000 Prius C Geekmobiles are being deployed nationwide. With the Geek Squad answering more than 5 million house calls a year, the fuel savings from switching to a more efficient hybrid cars means reduced emissions over the 12.6 million miles they'll drive per year. Read more in the press release below. Vehicle of Choice for Geeks? Toyota Prius c An armada of agents is about to roll out in Toyota Prius c. Their mission: to help people across America get the most from their technology. Starting today, Best Buy's Geek Squad will dispatch more than 1,000 of the vehicles – fully decked out as the new Geekmobile – nationwide.