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Jim Lentz exposes more details behind Toyota's move to Texas

Toyota's North American CEO Jim Lentz has already given us a rough idea of what prompted the company's surprise move to the Dallas suburb of Plano, TX from its longstanding headquarters in Torrance, CA. A new story from The Los Angeles Times, though, delivers even more detail from Lentz on the reasoning for the move, what other cities were considered and why the company's current host city wasn't even in the running.
Of course, one of the more popular reasons being bandied about includes the $40 million Texas was set to give the company for the move, as well as the state's generous tax rates. According to Lentz, though, the reason Toyota chose Plano over a group of finalists made up of Atlanta, Charlotte and Denver, was far simpler than that - it was about consolidating its marketing, sales, engineering and production teams in a region that's closer to the company's seat of manufacturing in the south.
"It doesn't make sense to have oversight of manufacturing 2,000 miles away from where the cars were made," Lentz told The Times. "Geography is the reason not to have our headquarters in California."

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."

Ford Fusion production scaled back just 3 months after it was accelerated

Three months after kicking off production of the Ford Fusion at its Flat Rock, MI factory, Ford Motor Company is taking steps to trim output in the face of heavily discounted competition from Toyota and a growing supply of vehicles.
The addition of Fusion production in Flat Rock - which also builds the Mustang - was meant to be what pushed the handsome mid-sizer past its arch-nemesis, the Toyota Camry. An extra facility building Fusions was also meant to curb the growing demand for Ford's highly profitable sedan.
But with word that Flat Rock would take "approximately" one extra week off for the holidays combined with an 88-day supply of Fusions - reportedly due in no small part to what Morgan Stanley analyst Adam Jonas called "aggressive discounting of the Camry" - some analysts are now beginning to wonder if Ford may have overextended itself by adding a second Fusion facility to the mix.