Toyota

Oct 12 2018

For Lean Production to Work, a Company Needs to Be All In | Ellen Rosen | The New York Times

 

“For a company in Chesterfield, Mo., it involved something as seemingly simple as attaching a trash can to an employee’s chair. For one in St. Louis, it meant leaving the cover off an electronic temperature controller. For others it’s meant gathering employees from the chief executive on down for what’s known as Kaizen events — based on the Japanese word for continuing improvement. What do these seemingly unconnected efforts have in common? They are approaches to what is known as lean manufacturing — or, more recently, lean production — aimed at streamlining production processes, enhancing employee engagement and increasing profits.”

Source: The New York Times(10/11/2018)

Michel Baudin‘s comments: Thanks to Kevin Hop for drawing my attention to this article. Like him, I do read The New York Times regularly and usually appreciate the quality of its reporting. This article, however, does not measure up. It reflects the conventional wisdom on Lean manufacturing which, if anything, explains why so many implementations fail.

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Aug 14 2018

BOMs at Toyota | Discussion on LinkedIn

I shared the BOM rap post with the TPS Principles and Practices group on LinkedIn, in order to tap into the TPS knowledge in this group, and this is what I learned from Todd McCann, Carey Boggess, Jeff Merriss, Hein Winkelaar, and Gary D. Stewart.

My thanks to all for their valuable input on the control of BOMs within Toyota and the uses BOM data is put to. What these responses did not address, however, is the information model for the BOMs, including what items are in and how BOMs are structured at Toyota, as opposed to other companies.

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Jul 27 2018

Lean Thinking: ingredients, incubation and diffusion | John Shook | Planet Lean

Ford and Toyota

“What does it really mean to say that lean thinking is not uniquely Japanese? First, it indicates that not all Japanese companies are ‘lean.’ […] Secondly, we have successful examples of lean applications all around the world – not just in Japan […]. We know these things to be true.

To say, however, that lean is not uniquely Japanese doesn’t mean that there is nothing Japanese about it. So, let’s explore this second, little explored, idea. […] by asking more questions. One critical question we can ask ourselves is: “Could have TPS emerged anywhere other than Japan?” And finally, “What, if anything, is Japanese about lean thinking?”

My attempt to address these questions – an ever-changing effort as I reflect more and the world around us keeps evolving – has taken the shape of the graph you see below, which illustrates what I call the “Toyota double funnels”. There are three main sections to the graphic:

  • The left funnel represents a selection of key ingredients that, combined, have led to the creation of Toyota’s way of working.
  • The spiral in the middle of the graphic represents the actual genesis of the Toyota Way, TPS, TPD, TMS and lean thinking, which can be traced back to a 30-year period of incubation, between 1950 and 1980.
  • The right funnel represents the diffusion of this body of knowledge around the world, which started around the time of the NUMMI experiment, in 1984.

[…]I believe the spread of lean has been both a matter of diffusion and of dilution.[…] Along with the dilution, there’s been more than a little delusion, aided by consultants selling things under the name of “lean” that are far from the original intent of the thinking, system, and application.”

John Shook’s double funnel is reproduced here. Click on it to enlarge or view it on Planet Lean to click on each item and see more details.

John Shook’s double funnel

Sourced through Planet Lean

Michel Baudin‘s comments: As usual, John Shook’s post is both grounded in deep knowledge and well written. The infographic is also clear and the popup boxes of information attached to each item on Planet Lean are a valuable enhancement.  But I still don’t buy everything in it.

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Jun 8 2018

New Karakuri Kaizen Video From Toyota

My colleague Kevin Hop drew my attention to this video of Kazuhiko Furui showing some examples of Karakuri Kaizen at Toyota, the training of Toyota employees in coming up with new devices, and the iterations that go into making them work. It goes deeper into the topic than the videos I had posted earlier.

This is part of a series of videos called econohito, that shows actions by Toyota employees to avoid wasting power or water, and to collect electricity from solar panels. Perhaps the best way forward for sustainable development would be to shift away from cars altogether, but that’s not what this is about.

#toyota, #karakurikaizen, #econohito

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May 31 2018

Stability Before Innovation | James Womack | The Lean Post

“Are we in the Lean Community lacking imagination and creativity? Indeed, do we take away the time and space for creativity and imagination from employees with our focus on standardizing work and our relentless process analysis […]? Or maybe this is backwards. Is it possible that […] a stable organization with stable processes enables successful innovation? […] Contrast Toyota’s methods with those of other companies generally believed to have brilliant, innovative ideas but no robust development, production, supplier management or even customer support processes, and which are short of funds. Not just Tesla but the whole VC-backed auto start-up industry come to mind.”

Sourced from The Lean Post

Michel Baudin‘s comments:

I don’t understand why Jim Womack restricts the discussion of stability and innovation to the car industry and the comparison with other companies to “VC-backed auto start-ups” that are short of funds. Toyota’s leaders grew the company by doing what they had to do to navigate the Japanese car industry. It is, in retrospect, a spectacularly successful model and worth studying. It is not, however, universally relevant.

Here in the heart of Silicon Valley, we view it as the worldwide hub of innovation, not the Nagoya area. Local entrepreneurs, VC-backed or not, have given us multiple generations of companies that are not exactly short of cash, like Hewlett Packard, Intel, Apple, eBay, Netflix, Google, Facebook,… Some of them are dabbling in the auto industry but most of their revenues come from elsewhere. It doesn’t make their practices and business models any less worthy of study than Toyota’s.

#innovation, #toyota, #siliconvalley

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May 22 2018

Toyota Attitude | Sam MacPherson | LinkedIn

Sam MacPherson just posted the following Toyota sign on LinkedIn:

Toyota Attitude

As usual with bilingual Toyota sign, the English is not great and the translation not perfectly accurate. With its tens of thousands of American employees, you might expect Toyota to use writers who know better than to mix nouns like “Teamwork” and a sentence like “We love Toyota” as items in the same list.

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