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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."

More powerful 2017 Toyota 86 takes over for the Scion FR-S

Scion is dead, and the FR-S name passes away with it. The rear-wheel-drive sports coupe isn't gone, though, because it's now the the 2017 Toyota 86. To match the new moniker, the latest model finally has a little extra power and more aggressive styling. The public debut will take place at next week's New York Auto Show, and sales begin this fall. "When we announced the transition of the Scion models to Toyota we hadn't planned on changing the names of our cars, but by popular demand, for our sports car, we decided to adopt the global name of 86," said Toyota Division Group Vice President Bill Fay. The 2.0-liter boxer-four's output grows to 205 horsepower and 156 pound-feet of torque – increases of 5 hp and 5 lb-ft – on manual-transmission models. The 86 still isn't the turbocharged rear-wheel-drive coupe of some people's dreams, but at least this is an improvement. (Buyers who opt for the automatic will have to make do with less power and fewer pedals.) Toyota also promises "additional performance" thanks to different gear ratios for the six-speed manual transmission, and there's now Hill Start Assist Control. New shock tuning and spring rates will affect the handling, too. The 86 wears a meaner look than the outgoing FR-S. The biggest change is a new front bumper with a large intake that stretches across the coupe's width, and the two sharp points along the bottom look like teeth ready to chomp down. Toyota also replaces the headlights and taillights with LED units. The twist-spoke wheels are a great accompaniment to the more aggressive look, too. The tweaks are more modest inside, including silver stitching and new materials for the dashboard and doors. Toyota will also display the C-HR crossover concept again in the Big Apple. We won't see the production version until later this year, and sales won't begin until spring 2017 as a 2018 model. Related Video: Toyota to 86 the FR-S Name New Toyota 86 and Charismatic C-HR Concept on Display at New York Auto Show TORRANCE, Calif., March 17, 2016 – With its new home comes a new name and more. The former Scion FR-S will debut as the 2017 Toyota 86 at the New York International Auto Show with interior and exterior changes, as well as suspension and powertrain upgrades. The new Toyota 86 will go on sale at all Toyota dealerships this fall.

Japan could consolidate to three automakers by 2020

Sergio Marchionne might see his dream of big mergers in the auto industry become a reality, and an analyst thinks Japan is a likely place for consolidation to happen. Takaki Nakanishi from Jefferies Group LLC tells Bloomberg the country's car market could combine to just three or fewer major players by 2020, from seven today. "To have one or two carmakers in a country is not only natural, but also helpful to their competitiveness," Nakanishi told Bloomberg. "Japan has just too many and the resources have been too spread out. It's a natural trend to consolidate and reduce some of the wasted resources." Nakanishi's argument echoes Marchionne's reasons to push for a merger between FCA and General Motors. Automakers spend billions on research and development, but their competitors also invest money to create the same solutions. Consolidating could conceivably put that R&D money into new avenues. "In today's global marketplace, it is increasingly difficult for automakers to compete in lower volume segments like sports cars, hydrogen fuel cells, or electrified vehicles on their own," Ed Kim, vice president of Industry Analysis at AutoPacific, told Autoblog. Even without mergers, these are the areas where Japanese automakers already have partners for development. Kim cited examples like Toyota and Subaru's work on the BRZ and FR-S and its collaboration with BMW on a forthcoming sports car. Honda and GM have also reportedly deepened their cooperation on green car tech. After Toyota's recent buyout of previous partner Daihatsu, Nakanishi agrees with rumors that the automotive giant could next pursue Suzuki. He sees them like a courting couple. "For Suzuki, it's like they're just starting to exchange diaries and have yet to hold hands. When Toyota's starts to hold 5 percent of Suzuki's shares, this will be like finally touching fingertips," Nakanishi told Bloomberg. "I absolutely do believe that we are not finished seeing consolidation in Japan," Kim told Autoblog. Rising development costs to meet tougher emissions regulations make it hard for minor players in the market to remain competitive. "The smaller automakers like Suzuki, Mazda, and Mitsubishi are challenged to make it on their own in the global marketplace. Consolidation for them may be inevitable." Related Video: