Don't confuse the use of robots with the issue of quality control.
It is true that there are cultural differences but the significance of Kaizen is make constant improvements that rely on input from people. In the end the robots are programmed by the workers so are only as good as the instructions programmed into them.

Many of the issues we are talking about are small things that can mainly be resolved by an improved set of specifications to suppliers or minor design changes. If the feedback from customers, or for that matter the workers, is not acted upon by management these small and constant improvements will never happen.

Two of the most serious problems in recent times seem to be the issue of cracked windscreens and poor quality leaf springs. The cost of warranty replacements of these items must have been quite significant. If the factory had immediately taken action to ensure the quality of these parts, supplied from outside sources, was up to standard then I am sure a lot of headaches could have been avoided.

Most other small problems could be resolved by small design changes and improvements in specifications most of which would contribute little added expense to the cost of manufacturing and saved a lot on the cost of unnecessary warranty repairs.

Phew! I'm glad I got all that off my chest.

Peter

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