Lets get some illumination and clear some smoke .
From ;
............acurazine.com/forums/showthread.php?t=345488
I broke this address so that " link charges etc " will be eliminated .
Add https.......... to make it work .
Like all things toyota , download and print copies - my opinion - the good stuff
always disappears .
Search engines/SEARCH ALTERNATIVES/TEXT QUOTES have interesting variances as well .
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EXTRACTED FROM ;
( roughly 7 - 10 % original text . ) My adds/comments in
( Bold . )
To preview ( short )
and purchase/subscribe / see some nice support material ;
http://online.wsj.com/article/SB115644337137844667.html
Larger extracts and complete copies available all over the Net - many automotive ( NON TOYOTA - mostly ) Forums and Blogs .
Key text ( in my opinion as relates to these engines and Sludge ) has *********** above and below
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WALL STREET JOURNAL 25AUGUST2006
Toyota May Delay New Models
To Address Rising Quality Issues
By
NORIHIKO SHIROUZU
August 25 , 2006 Page A1
Toyota Motor Corp., jarred by a surge of recalls and quality problems, ...................................... .................................................................
................................................................................................................................ But the fast-paced expansion has come with a cost: an increasing number of quality problems in North America, Japan and elsewhere ...........................................................................
.................................................................................................................
- So is the number of Toyota vehicles being recalled for quality problems.
Last year
( 2005 ) in the U.S. -- its
largest market by volume -- Toyota recalled 2.38 million vehicles, according to the National Highway Traffic Safety Administration. That's more than the 2.26 million it sold. Overall, the company sold nearly eight million vehicles world-wide.
This year
(as of 31JULY2006 ) , the company has recalled 628,000 vehicles in the U.S., and people familiar with the matter say it may soon recall an additional half-million vehicles.
( 885,000 - 1.2M - ??? ACTUAL YR. TOTAL ) The latest recall would affect the current generation of the Sienna minivan, because of concern that poorly designed locking devices for rear seats may fail to securely anchor them to the vehicle floor.............................................................
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Recalls also are on the rise in Japan, Toyota's second-largest market, where police and prosecutors are investigating possible professional negligence for shirking recalls
( ALL - NOT just the specific vehicle/balljoint issue - covers 16 - 20 YEARS of production ) for eight years.
( TIME NOT MODEL YEAR )
( ONE OF THE MOST MISUNDERSTOOD/SPUN? STATEMENTS OUT THERE . TWO NOT JUST ONE ( ASPECT(S) ) - OUT OF THREE TOTAL . )
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Investigators are
( also ) looking at whether a suspected faulty steering part on the Hilux Surf recreational vehicle may have
caused an August 2004 head-on crash that injured five people.
( ASPECT #3 ) The Japanese government has reprimanded the company and called for improved recall practices in the wake of the police probe .................................................
................................................................................................................................. over the past three decades, and the soaring number of recalls has been highly embarrassing for its management
( esp. the guys behind the scenes who have pushed too fast since the 1976 HONDA ACCORD ) . At a news conference last month, Toyota President Katsuaki Watanabe offered an elaborate apology.
"I take this seriously and see it as a crisis," Mr. Watanabe said. He then bowed deeply in front of the cameras, adding, "I want to apologize deeply for the troubles we have caused.".................................................
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................................................................................................................................
................The
( flawed ) strategy called for engineers to pump out more vehicles to fuel the company's growth around the world. Product-development bosses kept engineers on tight launch schedules. Toyota also began relying more heavily on computer-aided design tools to radically compress vehicle-development times by
skipping steps such as making physical prototypes to test componets .
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Using these high-tech tools, Toyota cut new-model development time to as short as about two years -- compared with three or four years in the past.
According to officials at the Toyota product-development and engineering center in Ann Arbor, Mich., virtual-engineering tools have helped the company slash the number of prototypes it builds per project
to fewer than 20 from 60 .
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But the new approach, which allowed its main advocate Yoshio Shirai, a senior managing director, to gain a seat on Toyota's board,
is now suspected
of contributing to the recent rash of
(sludge ? ) embarrassing quality glitches.
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Additionally, Toyota executives and engineers say, some mistakes are happening because computer-aided engineering tools have limitations that allow potential design flaws to slip through
.................................................................................................................
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A slowdown would follow a set of actions announced by the company
after the Japanese government's reprimand of its recall policies. In a report submitted to the government, Toyota said it would upgrade a new data network for sharing technical information and product-quality reports from customers in order to handle recalls more efficiently. It also will increase staff at its quality-control headquarters.
Earlier this year, Mr. Watanabe named two executive vice presidents --
including Akio Toyoda , a
scion of the auto conglomerate's
founding family -- as quality chiefs
to oversee various initiatives
( oh yeeass - VARIOUS initiatives FOR SURE !!! for building more quality into components and vehicle design.
( Of important note ; previous job duties listed include China and INTERNET ( Worldwide - think about that ....... )
.......................................................................................................................
Inside the company, spending more time doing quality-assurance tests on new and redesigned cars under development is seen as
vital to
regaining control of quality, say individuals close to the matter.
( So what happened to the 2007 camry ? )
By delaying introductions of some products, Toyota would conduct more quality checks on components and, in
some cases, create more prototypes to make sure thousands of parts and systems that comprise a typical car work as intended and verify their durability, these people say.
( Oh , I see .)
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Toyota also is accelerating
( better check the battery first - and the oil ) an application of what it describes as "preventive engineering"
-- an approach the auto maker has been implementing since the late 1990s
to forecast problem areas
( Sooooo..................does this mean they KNEW about sludge after ?????? ) based on engineering knowledge
( who , toyota ???? - engine engineering knowledge ????? ) accumulated over the years
( like sludge ?) and using extra caution
in designing those areas.
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The approach is based on the idea that most components of today's cars are proven technologies, and that most problems occur when, for example, engineers combine two or more parts to create a component system.
( Gee , would this be like traditionally weak toyota( engine ) short block assembly protocols plus troubled new tech Yamaha CYLINDER HEADS plus nonasbestos headgaskets ? ) Toyota engineers focus most of their attention on those "interface" areas to predict problems that might develop.
( Well .... , I bet they sure do now )
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Toyota also has made what one engineer describes as a "clear and conscious change" in the way it handles recalls
( NOPE - NOT ALL THE WAY - JUST AS LITTLE AS POSSIBLE ) in the wake of
a painful scandal involving an alleged
( fully confessed and known ) coverup of vehicle defects by Japan's Mitsubishi Motors Corp. a few years ago, which crippled sales and drove Mitsubishi to the brink of collapse.
( The above accident / 3 part criminal investigation/Gov. demand to account for/change and reprimand did it )
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"We used to do
quiet recalls called 'service campaigns' to deal with many defects,
but we're not going to hide anything any more , " said one senior engineer. "
Most of the known defects and issues are now handled through recalls."
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........................................................ - pace of new-model launches -- and pressure to keep product launches on schedule -- has given rise to what another senior engineer calls
" bonehead " mistakes.
( LIKE THE 3MZ - FE 3.0L V6 and the I4 2.2L 5SFE ? Finally , some truth and hope for the future . )
In Japan this year, for instance, Toyota discovered it had made the rear axle of one sport-utility vehicle with the material used for another SUV. Designs for the two rear axles are almost identical, but the metal materials used to produce them are different enough that mixing the parts up caused concern over the strength of the axle. A Toyota spokesman said there was a question of the strength of the axle but declined to elaborate .