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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's Mirai fuel cell car gets its own special showroom

If the car's unique, the showroom better be as well. That's the approach Toyota is taking with the Mirai, its first production hydrogen fuel-cell electric vehicle. In fact, the model is getting its own special showroom starting this Friday. The Japanese automaker is opening the showroom in Tokyo. The facility takes up two floors totaling about 1,800 square feet and, from the pictures, it looks to have a very Zen-like quality. Toyota will be displaying one Mirai vehicle and will have another vehicle available for public test drives available every Friday. Toyota started selling the Mirai in Japan late last year and has announced plans to debut the car in the US – starting in California – this fall at a base price of $57,500, or a lease option of $499 a month for 36 months ($3,649 is due at signing). Earlier this year, Toyota said it was going to bump production to 2,000 vehicles next year (and 3,000 in 2017) from 700 units this year. With such a ramp-up in store, Toyota will spend about $170 million increasing production capacity of the fuel-cell vehicle. That total probably doesn't take into account the stylish new Tokyo showroom. Related Videos: New Toyota Mirai Showroom in Downtown Tokyo Offers a Glimpse of the Future Tokyo, Japan, April 13, 2015-On Friday, Toyota will open a showroom to highlight the groundbreaking Mirai fuel cell vehicle, which went on sale last December. Located within a hydrogen station operated by Iwatani Corporation in Tokyo's Minato Ward, the space will serve as a hub for sharing information on fuel cell vehicles and hydrogen, with the aim of promoting a hydrogen-based society. In addition to having one Mirai on display and another for test drives, the showroom will use videos and other media to raise awareness about the features of the vehicle, the benefits of hydrogen and more. Overview of the Toyota Mirai Showroom Location 4-6-15 Shiba-Koen, Minato-ku, Tokyo Opening April 17, 2015 Floor area 1st floor84 m2; 2nd floor81 m2 Hours 9:00-17:00 Closed Tuesday (The Iwatani hydrogen station is closed on Saturdays, Sundays, and holidays) Display vehicles 1 Test ride vehicles 1 (available to public on Fridays only) Website http://toyota.jp/mirai/showroom/ (Japanese only)

Toyota expands Takata airbag inflator recall

The Basics: Toyota will recall 198,000 examples of the 2008 Corolla and Matrix and the 2008-2010 Lexus SC430. The Problem: The vehicles contain Takata's dual-stage inflators in their front passenger airbags, which could rupture in a crash. Injuries/Deaths: None reported in this population of vehicles. However, experts believe Takata's inflators have links to at least ten fatalities. The Fix: Dealers will replace the part with a newly manufactured one. If You Own One: Toyota will notify owners about the recall by first-class mail in March and will send a remedy letter in June when the parts are ready. TOYOTA EXPANDS TAKATA AIRBAG SAFETY RECALL TORRANCE, Calif., March 2, 2016 – Toyota Motor Sales, USA, Inc. today announced that it is expanding two of its recalls involving Takata front passenger airbag inflators. This will add model years of certain vehicles previously recalled and will cover all remaining dual-stage front passenger inflators of a particular type, as a precautionary measure. Approximately 198,000 Model Year 2008 Corolla and Corolla Matrix and Model Year 2008-2010 Lexus SC430 vehicles will be added to the recalls. The involved vehicles are equipped with a Takata-produced dual-stage front passenger airbag inflator which could potentially be susceptible to rupture when deployed in a crash. All known owners of the affected Toyota / Lexus vehicles will be notified by first class mail. Dealers will replace the airbag inflator or the airbag assembly with a newly manufactured one at no cost. Information about automotive recalls, including but not limited to the list of involved vehicles, is subject to change over time. For the most up-do-date Safety Recall information on Toyota, Lexus or Scion vehicles, customers should check their vehicle's status by visiting toyota.com/recall and entering the Vehicle Identification Number (VIN). Safety Recall inquiry by individual VIN is also available at the NHTSA site: safercar.gov/vin. For any additional questions, customer support is also available by calling Toyota Customer Service at 1-800-331-4331, or Lexus Customer Service at 1-800-255-3987. ###