Avalon Xls on 2040-cars

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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."

2015 Toyota Sienna

It's hard to love a minivan, but it's very, very easy to use one. More than any other kind of vehicle - save a panel van, perhaps - the minivan is the most appliance-like of four-wheeled transportation devices. And most minivan buyers don't need to love their purchases; they just need to use them. So when it comes to a minivan's driving dynamics, who cares?
Well, we do. So we perked right up when Toyota talked about refinements it made to the 2015 Sienna, starting with some 142 added spot welds made to the body structure. Normally not stop-the-presses stuff, but Toyota says the added reinforcements prompted Sienna engineers to recalibrate the springs and shocks for improved handling, and our very limited wheel time along the (admittedly benign) roads on the Big Island of Hawaii revealed the 2015 Sienna SE model's handling to be tidier and more engaging than you'd expect for a porky, 4,560-pound, eight-passenger box on wheels.
Driving Notes

Australia may offer money to keep Toyota making cars there

In the wake of last month's announcement that Ford will cease automotive and engine production in Australia after 2016, many are wondering what the country's other automakers will do. Holden has already confirmed it will stay the course despite Ford's exit.
Much of the GM subsidiary's reason for sticking around has to do with a deal made last year between Holden and the Australian government. In order to secure a GM investment of $1 billion and a commitment to keep manufacturing in Australia through 2022, the government threw in an extra $215 million. According to Australia's Minister for Innovation and Industry, Greg Combet, the government is now in talks with Toyota for a similar deal.
Toyota operates one plant in Australia, the Altona manufacturing and engine plant in Victoria. The facility produces the Camry, Camry Hybrid and Australasia-only Aurion for both the local market and export. The report from GoAuto indicates that negotiations with the Australian government would include adding production of a third, all-new model at Altona, possibly the new RAV4, because it shares many parts with the Camry.