Learning from failure [Manufacturing Safety]

First, let's briefly review the facts. Since 2002, when Toyota introduced an electronic throttle control system, there have been a spate of what are termed 'unintended acceleration' incidents involving Toyota vehicles. Several investigations by the US National Highway Traffic Safety Administration duly followed, and there were a couple of small recalls. Then, in August 2009, came the harrowing deaths of California Highway Patrol officer Mark Saylor and three members of his family. In a recorded emergency call, the cautious and experienced officer can be heard saying that the accelerator was stuck, and that the brakes weren't working. As he approached an intersection, his last words were: "Hold on and pray" Finally prompted to acknowledge a problem, Toyota subsequently recalled 2.3 million vehicles, blaming an American supplier for faulty workmanship. But the supplier fought back, pointing out that they had only become a supplier in 2005 three years after reports of unintended acceleration first surfaced. In all, one American Firm of safety consultants has Identified 2,262 instances of the problem, leading to 819 crashes and 26 deaths. The world's media previously fond of extolling Toyota's Just-in-Time productions systems and quality-conscious virtues now rounded on the company, which quickly found its reputation in tatters. Public apologies soon followed from Toyota president Akio Toyoda, the grandson of the company's founder, as did still further recalls. Yet at the time of writing, no firm cause has conclusively been identified, and Toyota's reputation remains troubled.