In among the robots, veteran Toyota staffer says manual labor is key to success

Fri Mar 27, 2015 8:45am EDT
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By Chang-Ran Kim

TOYOTA CITY, Japan (Reuters) - In a corner of Toyota's oldest factory, the Japanese carmaker's longest-serving employee preaches the benefits of craftsmanship, saying manual labor is the key to success in a highly automated automotive industry.

Mitsuru Kawai, 67, joined Toyota's technical academy from junior high school more than half a century ago, and believes that even in today's sleek, streamlined, robot-filled factories there's a place for manual skills to be learned, honed and encouraged.

The world's biggest automaker will this year launch its first car as part of its Toyota New Global Architecture (TNGA) initiative - where common platforms and powertrains will be used across many models, cutting production costs by as much as a fifth.

This should make production processes "simpler and slimmer" by cutting down on the variations of parts across the range of models. But Kawai, senior technical executive, has made it his mission to set aside part of each Toyota factory for manual labor - an area where creative ideas keep flowing.

"Today's automation is the result of quantifying, standardizing and building in the exceptional skills that people honed by hand," Kawai told reporters at the Honsha plant on Friday, noting that even the model for the new TNGA platform was hand-forged, then worked into a blueprint.

"To keep building better cars, we have to take our manual skills to the next level. Machines can't train machines," said Kawai, the last surviving employee to have worked with Taichi Ohno, the founder of the vaunted Toyota Production System, which gave the world 'just-in-time' production.

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A man walks past Toyota Motor's logo at the company's showroom in Tokyo November 5, 2014.  REUTERS/Toru Hanai