Dec 17 2022
Several sites on the Van of Nerds tour in France in 9/22 maintain skills matrices on the shop floor. It means that the value of the skills matrix is widely known. Several questions must be answered to make it effective:
Feb 20 2022
[Featured image from Edward Tufte’s Envisioning Information)
Tracey Richardson started a spirited discussion on LinkedIn just by posting this quote, presumably from Toyota training materials, and asking “what else would you add to describe ‘Visual Management’”:
Dec 7 2020
Thanks to Jeffrey Liker for providing additional details on the transformation of this tool. Initially, Toyota used it occasionally with suppliers. The Lean Enterprise Institute (LEI) turned it into the Value Stream Maps (VSM) that it has promoted as foundational to Lean.
Oct 30 2020
Next to SPC, Design of Experiments (DOE) is the most common topic in discussions of Statistical Quality. Outside of niches like semiconductors or pharmaceuticals, however, there is little evidence of use, particularly in production.
At many companies, management pays lip service to DOE and even pays for training in it. You must “Design experiments” if you pursue continuous improvement.
In manufacturing, DOE is intended to help engineers improve processes and design products. It is a rich but stable body of knowledge. The latest major innovation was Taguchi methods 40 years ago. Since then, Statistics has been subsumed under Data Science and new developments have shifted in emphasis from experimentation to Data Mining.
Experimentation in science and engineering predates DOE by centuries. Mastering DOE is a multi-year commitment that few manufacturing professionals have been willing to make. Furthermore, its effective use requires DOE know-how to be combined with domain knowledge.
Six Sigma originally attempted to train cadres of engineers called “Black Belts” in a subset to DOE. They then served as internal consultants to other engineers within electronics manufacturing. Six Sigma, however, soon lost this focus.
Sep 26 2020
The post on Does Toyota Use SPC? elicited many comments on LinkedIn. Some suggested that it was scoping SPC too narrowly when contrasting it with Toyota’s approach. In fact, SPC as referenced in the post is the body of knowledge described in the American literature on quality and taught in professional courses.
As to why Toyota is not using SPC, the answer is simple: SPC is about process capability and the quality problems Toyota addresses in 2020 are not due to lack of process capability. In industries that lack process capability, modern data science outguns the old SPC toolkit but that is a different discussion. The most vital question raised in the comments was why we have been not learning Toyota’s approach to quality. In the past 30 years, American industry has learned “Lean Six Sigma” instead.
The comments also enriched the public sources of information cited in the post with corroboration by current and former employees of Toyota.
Aug 9 2026
Houses of TPS
The “House of TPS,” is popular in the US and Europe as a summary of the Toyota Production System. We trace its origins and review its design and components in a 2007 version from Toyota Europe. Nigel Thurlow posted it on LinkedIn and says he was in the room when his Toyota colleagues drew it. We explore why the Greek temple theme was adopted, and suggest it may have been to make TPS appear less foreign to Americans.
Once stripped of the temple, it is a stack diagram, and we review the content of the boxes from bottom to top. While popular and widely copied in multiple variants by American consultants, the only Houses of TPS I could find in Japanese are translations of Jeffrey Liker’s.
While the House of TPS resonates with Americans, even the version developed within Toyota fails to provide more than a list of keywords, while leaving out key elements. The best it can do is motivate the reader to dig deeper.
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By Michel Baudin • Management 0 • Tags: House of Lean, House of TPS, Lean, Toyota, Toyota Production System, TPS