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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 promises Hybrid-R concept for Frankfurt

Toyota will be bringing a new concept car to the Frankfurt Motor Show next month. Dubbed Hybrid-R, Toyota says the concept will feature the same Toyota Hybrid System-Racing tech found in the automaker's latest endurance car, the TS030 Hybrid.
That car took second place at the 24 Hours of Le Mans, with a gas-powered, 3.4-liter, naturally aspirated V8 and a capacitor-based hybrid system. The result was 530 ponies from the engine and an extra 300 horsepower from the electric motor and batteries.
Toyota's press release came with but one image, a new Hybrid badge which is a far cry from the Hybrid Synergy Drive label found on the automaker's other offerings. There's really not much else to go on yet, but the news that Toyota is already adapting its racing tech for a concept bodes well for the future of exciting, hybridized offerings from the automaker. We'll be at Frankfurt live, and will be sure to bring you all the news on this new concept as it becomes available.

Toyota's Euro Aygo spied in prototype form

The five-door version of the next-generation Toyota Aygo, a Euro offering cloned by the Peugeot 107 and Citroën C1, has been caught out on the town wearing all black. Facelifted early last year, predictions are that the next version of the city car will be slightly lower and wider than the current car, with improved ergonomics and materials. Based on what little can be seen for now, a new intake and headlight treatment should be on the menu in front, with taillights placed higher on its backside.
A three-door version is expected, but a gasoline-hybrid model is also rumored, along with power and fuel economy improvements to the three-cylinder engine that presently puts out 67 horsepower and 69 pound-feet of torque.
We should see it next year, along with the new Citroën C1 and Peugeot 108.