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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 GT86 convertible could debut in March

The dates are lining up, now we wait to see how the badges align. Just before the Toyota GT 86/Scion FR-S/Subaru BRZ line-up was introduced at the Tokyo Motor Show last year, there was a report that Subaru was considering a convertible while Toyota wouldn't even comment on it. That got swapped around when earlier this year the chief engineer on Toyota's side said a convertible was coming, and then a Scion FR-S droptop was confirmed for early 2014.
Autocar now reports that the Toyota GT 86 convertible will make its first appearance at the 2013 Geneva Motor Show in March. In a car whose specs like weight, packaging, horsepower and center of gravity were all tightly controlled to get the most from the least, the changes necessitated by chopping the roof could make this a very different car. It's said to employ a fabric roof to keep a "small" weight gain check, and the suspension will be softened to work more harmoniously with the decreased body stiffness. And somewhere in all that the back seat and trunk space will need to take a hit.
In other news, Autocar says the hi-po GT 86 with some kind of capacitor system instead of batteries is being worked on for 2015.

GM outsold VW globaly in first quarter, Toyota reports numbers next week

General Motors released its first quarter sales figures this week, reporting that it sold 2.36 million cars and trucks worldwide. That figure represents an increase of 3.6 percent when compared to the same period last year. GM's growth was attributed to many factors, including global Cadillac sales that were up 26 percent and Chevrolet posting a one percent increase over last year (this marked Chevy's tenth straight year of record global sales).
Volkswagen came in just behind GM, as the German automaker reported global sales from January through March at 2.27 million vehicles, an increase of five percent when compared to last year. While that number was strong, VW is cautioning that markets outside China and the US, such as those in Europe, are becoming a challenge as economies falter.
Yet to report sales is Toyota, current holder of the global world sales crown (the Japanese company sold 9.75 million cars last year, against 9.29 million sold by GM and 9.1 million vehicles sold by VW). Even though GM and Toyota both say they don't care who sells the most units, it is unquestionably a strong bragging point and sales equate to revenue. That said, Toyota will report its first quarter numbers next week.