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Toyota recalls slew of models for possible airbag calibration defect

Toyota is recalling sixteen models from the 2009 to 2013 model years over a potential issue with passenger seat airbag calibration. In spite of the large number of different Toyotas covered by the recall, just 3,235 units are included. These were vehicles installed with accessories like leather seat covers and headrest DVD systems by Southeast Toyota Distributors, and during the modifications the passenger seat occupant sensor system might not have been calibration tested. If the sensors aren't set up properly, the passenger airbag might not work as it should.
Affected models include: Avalon, Camry, Camry Hybrid, Corolla, 4Runner, FJ Cruiser, Highlander, Highlander Hybrid, Prius, Prius V, Rav4, Sequoia, Sienna, Tacoma, Tundra and Venza. Scroll down for the relevant model years for each.
The National Highway Traffic Safety Administration indicates that the recall will begin this month. Southeast Toyota will inform owners, at which time they can take their Toyotas to dealers for testing and repair. The complete bulletin from the NHTSA with more information is below.

Toyota recalling 800k Camry, Avalon and Venza models for AC issue

Toyota has announced plans to voluntarily recall 803,000 vehicles from model years 2012 and 2013, over concerns with the air conditioning condenser housing. The recall covers the Camry, Camry Hybrid, Avalon, Avalon Hybrid and Venza, although the exact split between affected models wasn't available.
According to Toyota, the condenser can leak onto an airbag control module, which in turn could cause a short circuit. In most cases, this will just lead to an airbag warning light, but in rarer instances, the airbags could fail to deploy or pop out of their own accord. There's also a concern over a loss of power steering if the airbag control module develops a short.
It's unclear if there have been any injuries or crashes relating to the defects. Toyota will begin informing owners of affected vehicles via first class mail, and will ask them to report to dealerships for recall work, involving the installation of a cover on the condenser housing.

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."