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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."

Recharge Wrap-up: New and old Audis get greener, as does US electricity

Audi has made environmental improvements to the its TT while boosting performance. The new TT sees an 11-percent reduction in emissions, and up to 14 percent more power. Audi says that each TT will save around 5.5 metric tons of greenhouse gas emissions over its lifecycle. Additionally, the TT's manufacturing process has been cleaned up a bit, reducing emissions by about nine percent. Read more in the press release, below, or see Audi's lifecycle assessment here. Speaking of greening up Audis, Al Swackhammer of Washington converted his 1960 Audi DKW 1000S to run on electric power. Swackhammer first fell in love with the Audi Ur-Quattro, became an enthusiast of Audi and Volkswagen cars, and has owned nothing else ever since. With his DKW, he combined his passion for the classic car with his responsibility to the environment. "I am pleased that I did this project," says the happy owner, "and I enjoy driving it very dearly." Meet the man and his beloved electric Audi DKW in the video below. Toyota has chosen a sustainable design firm, Corgan, as the lead architect for its new North American headquarters. The new campus will be built in Plano, TX, and will be the workplace of about 4,000 Toyota employees. Corgan, who has already done 47 LEED certified projects, is already designing a temporary office for the site while it finishes the project. Toyota expects to begin working from the site in late 2016 or early 2017. Learn more in the press release below. In July, all new electrical generating capacity in the US came from renewable sources. The Federal Energy Regulatory Commission's Office of Energy Projects' newest "Energy Infrastructure Update" report says new electric generation put into service last month came from wind (379 megawatts), solar (21 megawatts) and hydro (5 megawatts). So far this year, 53 percent of new energy generation capacity has come from various renewable sources, and none from coal or nuclear. Currently, renewable energy accounts for 16.3 percent of the US electric generation capacity, providing about 14 percent of actual electricity. Read more in the press release from the Sun Day Campaign below. Positive life cycle assessment for the new Audi TT Compact sports car scores high for dynamic performance and efficiency Emissions reduced by 11 percent compared with predecessor Customer benefits from the very first mile Ingolstadt, August 18, 2014 – Dynamic performance and efficiency: The new Audi TT* impressively combines both qualities.

April Fools' Day brings Jeep Sedan, Hyundai N Roadster, Toyota Yaris pickup and more

There is one day out of the year when public relations professionals have permission to lie to journalists and to the public: April Fools' Day. Manufacturers release details about wild, weird and wacky new technology, concept vehicles and services. Some take it to obvious outlandish extremes (Jeep Sedan anybody?), while others plot to mislead with products that are just outside the realm of possibility. Check out all the "jokes" below. BMW Motorrad BMW doesn't want to exclude anybody from experiencing the thrill of high-level racing, so it is introducing 'iRace" autonomous programming on its S 1000 RR sport bike. It includes beginner, sportsman, advanced and unlimited driving modes, and stores GPS information for all Superbike world championship tracks. Hyundai Hyundai is wrong for this. The Hyundai N Roadster is the work of South Korean designer Yeonjoon Park and features a 2.0-liter turbocharged engine, rear-wheel drive and a hard convertible top. Hyundai says this is a "concept (for now)," but we think it'd make a seriously great Mazda Miata competitor. Honda Honda wins the award for the best interactive gimmick, as its press release for the '90s-inspired special-edition Pastport includes a live hotline number with a message from Fred Savage. Call 1-833-PASTPORT for more information. Jeep Put the Jeep Cherokee face on the Chrysler 300's body, and voila! The 2019 Jeep Sedan is born. We can't decide if the name or the rendering is better. Land Rover Accessibility to charging ports is of major concern to anybody with a plug-in vehicle. So, with the recent launch of the Range Rover P400e and Range Rover Sport P400e, Land Rover is putting forth an effort to install more stations around the globe. First up is Scotland's Isle of Skye. Adventurers need juice too! Lexus Australia Lexus expands its Encore service to include doggos. The new service, called Enpaw, will take pups to luxury boarding kennels in style. Toyota U.S. Toyota created the Yaris Adventure pickup for "those who want to tell their friends they own a truck but never veer off pavement." It's part Mazda 2, part RAV4, 100 percent ute and it looks ... great? Creating a new segment might be all fun and games to Toyota, but Ford is reportedly considering a Focus-based ute in a similar, albeit larger, style. Toyota Australia Toyota is launching a new HiAce van, and it's already getting a limited-edition variant called the PieAce.