Idle Workers Busy at Toyota

Idle Workers Busy at Toyota

Instead of sending the workers home, as the Detroit makers often do, Toyota is keeping them at the plants, though. The employees spend their days in training sessions designed to sharpen their job skills and find better ways to assemble vehicles.

At its Princeton plant, by contrast, Toyota is using the down time to hone its workers’ quality-control and productivity skills. The company has pledged never to lay off any of its full-time employees, who are nonunion.

Jim Lentz, president of Toyota Motor Sales, the company’s U.S. sales unit, said the company believes keeping employees on the payroll and using the time to improve their capabilities is the best move in the long run. “It would have been crazy for us to lose people for 90 days and [then] to rehire and retrain people and hope that we have a smooth ramp-up coming back in,” Mr. Lentz said.

In Princeton, senior plant manager Norm Bafunno said he can already see the benefits of the training. Mr. Bafunno cites a Teflon ring designed by an assembly worker during the down time that helps prevent paint damage when employees install an electrical switch on the edge of a vehicle’s door.

Mr. Mason, a 40-year-old former firefighter, added: “One of the major things that everyone is grateful for is that they thought enough of us to keep us here.”

Toyota continues to show intelligence, long term thinking, respect for people… in their management decisions. I worry they may capitulate and make explanations about how the economy forced them to abandon their principles. I hope they prove that cynical fear in me to be wrong, in their case.

Related: Bad Management Results in LayoffsToyota Management Not Close to Being DuplicatedToyota’s Commitment to CustomersPeople are Our Most Important AssetJim Press, Toyota N. American President, Moves to Chrysler

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2 Responses to Idle Workers Busy at Toyota

  1. Bill Pearson says:

    I am glad that some companies are thinking through the issue of what happens when lean works. Lean reduces lead time limits inventory and reduces labor. When economic conditions cause orders to dry up the lean factory stops producing product and waits on new orders. What do you do with the people? There will be many US firms which will simply take the destructive act of idling workers and simply reduce costs in the short term. When conditions improve the training of new people and the associated learning curve and quality issues will dominate their production problems for a period of time.

  2. Pingback: Curious Cat Management Improvement Blog » Toyota Posts Loss of $6.9 Billion in Last Quarter

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