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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, Morgan Spurlock say hydrogen can be bullsh*t

Toyota wants the world to know that it's not full of crap about hydrogen as the future of fuel. Months before the Mirai arrives at dealers on the West Coast, the automaker is trying to get the word out through documentary series called Fueled by Everything. In the first episode, director Morgan Spurlock (best known for Super Size Me) shows how to make the futuristic fuel cell sedan run on a load of dung. After some processing, anyway. The whole point of the series is to show viewers the myriad sources available to generate hydrogen, and Toyota starts at an attention-grabbing extreme. A pickup truck takes a bed full of cow manure and demonstrates the steps needed to make it into hydrogen for the Mirai. Of course, the new model gets lots of screen time, too. For those in the audience curious to learn more, Toyota also digs a little deeper into the generation process on the series' website. Fueled by Bullsh*t Toyota Taps Morgan Spurlock to Direct First Video in "Fueled by Everything" Series TORRANCE, Calif. (April 22, 2015) – Sometimes reality stinks. Toyota has tapped award-winning documentary filmmaker Morgan Spurlock to show how calling hydrogen fuel cell vehicles "bullsh*t" isn't far from the truth. "Fueled by Bullsh*t" is the first online video in a multi-part "Fueled by Everything" series aimed to educate a broad audience about the innovative ways hydrogen fuel can be made from renewable sources. Spurlock directed the 3-minute piece which features a dairy farmer and mechanical engineer as they follow cow manure from a mooing supply source to its ultimate use in powering the hydrogen fuel cell electric Toyota Mirai. "This project gave us the opportunity to dive into a world that most people don't understand but has the potential to change our world," said Spurlock. "Witnessing manure, something most of us view as being pretty disposable, being transformed into hydrogen fuel to power a car was pretty remarkable. I think this short film is pretty compelling evidence of what could be possible in the years ahead." Beyond high quality dung, hydrogen can be manufactured from other renewable energy sources like solar, wind and biogas from landfills. These production methods can result in a domestic and locally sourced fuel that powers the Mirai while emitting only water vapor from the tailpipe. The multi-series video campaign is launching through the Toyota Mirai website (www.toyota.com/mirai) and additional digital properties with paid online media support.

Toyota hydrogen vehicle visits CES, on sale in US in 2015

If there was ever any doubt that Toyota loves hydrogen vehicles, just listen to some of what Bob Carter, senior vice president of automotive operations for Toyota Motor Sales, USA, said today at the Consumer Electronics Show (CES) in Las Vegas: "Fuel cell electric vehicles will be in our future sooner than many people believe, and in much greater numbers than anyone expected." "Hydrogen works beautifully with oxygen to create water and electricity and nothing more." "This [hydrogen] infrastructure thing is going to happen." "I believe what I'm going to tell you about today is going to change our world." Sounds like love is in the air. In all seriousness, Toyota is incredibly bullish on the future of hydrogen as a part of the automotive landscape, and is now gearing up for the 2015 launch of its hydrogen sedan. The concept version of the car was shown for the first time at the Tokyo Motor Show last fall and is making its North American debut at CES today, alongside the still-under-camo engineering prototype. The reasons for Toyota's hydrogen confidence? The debut vehicle is supposed to be a "reasonably priced" car that has a range of 300 miles and a refueling time of about five minutes. Carter highlighted the engineering work that Toyota has done over the past decades to get the fuel cell system downsized while upping power output to over 100 kW. He also said the vehicle will have carry enough energy to power a house for a week, so company engineers are working on an export power supply device. The H2 Toyota sedan will start sales in California (the only state in the US where there are currently any hydrogen stations) next year. The automaker is working with the University of California Irvine's Advanced Power and Energy Program (APEP) to figure out where to build the next series of public hydrogen fueling stations. Today there are ten, but the model Toyota is using "is based on the assumption that owners want to reach a refueling station within 6-minutes" and shows that 68 stations would be able to serve around 10,000 hydrogen vehicles. 'Toyota Car of the Future' On Sale Next Year; Opens 2014 Consumer Electronics Show (CES) Reasonably priced hydrogen fuel cell electric targets 300-mile range, 3-5 minute fill-up LAS VEGAS (Jan. 06, 2014) – "We aren't trying to re-invent the wheel; just everything necessary to make them turn," said Bob Carter, senior vice president of automotive operations for Toyota Motor Sales (TMS), U.S.A.