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In Surprising News, Toyota is Replacing Some Robots with Humans |
Материал из категории News of logistics (in English) |
20.04.2014 15:34 |
Many know the saga of GM and then CEO Roger Smith's disastrous foray into robotics in the 1980s, when plans to substantially automate auto production ran into a painful wall of inflexibility and high maintenance. Robots, of course, have come a long way since then. Modern auto factories, such as the Tesla electric car plant in According to Bloomberg, the world's largest car maker believes it has been losing "craftsmanship" in its processes and workers. To get some of that back, humans are now back replacing the machines in some areas.
"We need to become more solid and get back to basics, to sharpen our manual skills and further develop them," says Mitsuru Kawai, who has been at Toward that end, people are taking the place of machines in plants across Japan, so that workers can develop new skills and figure out ways to improve production lines and the car-building process. Kawai believes, for example, that learning how to make car parts from scratch gives younger workers insights they otherwise wouldn't get from just picking parts from bins and conveyor belts, or pressing buttons on robotic machines. At some 100 manual-intensive workspaces introduced over the last three years across This new Robotics are still a key element of Toyota's current and future processes too, of course, but the company wants to ensure human knowledge is not lost in the race to a more automated future, knowledge the company believes can drive even more savings from using robotics. For example, at Such an approach is not reserved just for crankshafts. While at Toyota's heavily automated Motomachi plant nearby some 760 robots are used one way or another in 96% of the factory's production processes, Kawai has also introduced multiple more manual lines in each of Toyota's factories in Japan. "We cannot simply depend on the machines that only repeat the same task over and over again," Kawai said. "To be the master of the machine, you have to have the knowledge and the skills to teach the machine." A basic problem with factory automation is that it can lead to the halt of progress, where continuous improvement proves difficult to achieve as the robots simply do their work each day. Part of what Under that regime, newcomers would be given three months to complete some sort of factory improvement project. The direct supervisors of those newbies might be able to solve the problem in some three weeks. The next management level up might need only three days to come up with the solution. But somehow, under conditions of rapid growth in vehicles produced annually, that mindset and approach was lost, believes "Fully automated machines don't evolve on their own," Takahiro Fujimoto, a professor at the Kawai, now 65 years old, started at a
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