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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."

Japanese dealer petitioning Lexus for luxury van [w/poll]

Used to be that if you wanted a luxury automobile - especially one to be chauffeured around in - your choices were basically limited to a sedan. It could be bigger or smaller, more or less expensive, depending on your needs and budget, but it was always going to have four doors and a trunk. But these days the rich and famous are looking elsewhere for their commodious forms of pampering transportation. There are, of course, the crossovers and SUVs, which only seem to be getting bigger and more expensive thanks to the likes of the Mercedes-Benz G-Class, Range Rover L and upcoming Bentley sport-ute. But luxury vans are becoming the new big thing.
That's the point that one dealer in Japan is trying to make to Toyota. The dealership owner himself reasons that if he's going out on the town, he's likely to take his chauffeured Lexus LS. But if he's taking a few friends along, even the biggest sedan isn't going to cut it. So he takes a Toyota Alphard (pictured above, also known as the Vellfire), a JDM van that's even bigger than a Voxy/Noah or Sienna but hardly a high-end affair. That's why he's asking Lexus to make a luxury van.
The idea may seem a little far-fetched, but isn't without precedent. It didn't take much for Lexus to transform the Land Cruiser into the LX and thus create its first luxury SUV. And as Mercedes has shown with pimped-out versions of the Sprinter and now with the debut of the new V-Class in Geneva, there's clearly a market for it... in some countries, anyway. The only question in our minds is how long it's going to take other luxury automakers to catch on, because let's face it: the Chrysler Town & Country ain't gonna cut it for those used to be driven around in a Maybach.

Sports 800 is a progenitor of Toyota performance

There's an automotive axiom that claims it's more fun to drive a slow car fast, than a fast car slow. If that's the case, then pushing a Toyota Sports 800 around must be one of the most exhilarating experiences behind the wheel in the world. With just 800cc of displacement from a two-cylinder boxer engine, the focus is on finesse over outright speed. Still, it's a fantastic page in Toyota's performance history, and Petrolicious takes a ride with a man who owns a meticulously restored 1967 example in its latest video.
The Sports 800 used the classic cost-saving strategy in the auto industry of taking parts from a standard model in the lineup and modifying it into a sports car. In this case that meant borrowing the engine from the plebian Toyota Publica, beefing it up for more power and clothing the whole thing a in beautifully shaped, wind-tunnel-honed body.
The look of these lithe, targa roadsters is the exact opposite of the rather dull styling sometimes associated with Toyota today. Everywhere you look there are louvers, vents or curves to draw the eye. Check out the latest Petrolicious video for a detailed look at the history of this rare model that's largely unknown on this side of the Pacific.