Category Archives: Lean thinking

Toyota Execution Not Close to Being Copied

Posted on May 7, 2008 by John Hunter

The Open Secret of Success Toyota’s innovations, by contrast, have [focused] on process rather than on product, on the factory floor rather than on the showroom. That has made those innovations hard to see. But it hasn’t made them any less powerful. At the core of the company’s success is the Toyota Production System, which took shape in the years after the Second World War, when Japan was literally rebuilding itself, and capital and equipment were hard to come by. … Continue reading →

Posted in Deming, Innovation, Lean thinking, Management, Management Articles, Popular, quote, Toyota Production System (TPS) | Tagged , , | 2 Comments

Toyota Canada CIO on Genchi Genbutsu and Kaizen

Posted on April 24, 2008 by John Hunter

What’s driving Toyota Canada’s success? – CIO reveals all for Hao Tien, chief information officer (CIO) at Toyota Canada Inc. those two Japanese phrases – Genchi Genbutsu (go and see) and Kaizen (continuous improvement) really capture it all. … the innovation wasn’t in the technology, but in the way the various partners were brought together to agree upon processes, which were then consistently executed. CustomerOne is only project of its kind in the Toyota empire. … A computer system links … Continue reading →

Posted in IT, Lean thinking, Management, Management Articles, Toyota Production System (TPS) | Tagged , | 3 Comments

Gary Convis is the New CEO of Dana

Posted on April 17, 2008 by John Hunter

Another former Toyota USA leader is talking a leading role at another company. Gary Convis from Toyota retired last year. Related: articles by Gary Convis – Toyota Management Speech by Gary Convis – Toyota Management Develops the New Camry – Quality Conversation with Gary Convis – Jim Press, Toyota N. American President, Moves to Chrysler Dana Holding Corporation Names Gary L. Convis Chief Executive Officer Dana Holding Corporation (NYSE: DAN) emerged from bankruptcy recently and today announced that it has … Continue reading →

Posted in Lean thinking, Management, Manufacturing, Toyota Production System (TPS) | Tagged , | 1 Comment

A Programmers Take on Agile Software Development

Posted on April 6, 2008 by John Hunter

A Case for Agile: Benefits for a Programmer’s Career by Theodore Nguyen-Cao Through agile development, I’ve been able to deliver working software time and time again. I’ve been exposed to all different aspects of the business. I’ve learn what I like and don’t like to do. I’ve learn what pieces of business I’m interested in and the pieces I don’t care much for. I’ve developed some really good working relationships. I’ve tackled some hard problems. I’ve learned to respond and … Continue reading →

Posted in Career, Lean thinking, Management, Process improvement, Software Development | Tagged , , , | 3 Comments

Tesco Pauses USA Expansion

Posted on March 31, 2008 by John Hunter

Pausing for reath at fresh & easy (Tesco’s USA stores) We’ve opened 31 stores in 66 days so far this year…now we’re pausing for breath… However, after opening our first 50, we planned to have a 3 month break from openings, and other than a couple more in Phoenix, we’re taking it (albeit, in our usual fashion, with 59 stores already open). … We’ve learnt a huge amount about running the operation, and talked to thousands of customers about what … Continue reading →

Posted in Lean thinking, Management | Tagged , | 1 Comment

Webcast on 2-Bin Systems

Posted on March 11, 2008 by John Hunter

Illustration of how 2-Bin Systems work, by Bill Hanover. Related: Overall Equipment Effectiveness (OEE) video by Bill Hanover – Messiness is Bad – Drum-Buffer-Rope Example – lean manufacturing resources

Posted in Lean thinking, Management, Quality tools, webcast | Tagged , , ,

Lean Manufacturing Saving Jobs Again

Posted on March 2, 2008 by John Hunter

Lean manufacturing saving jobs Keiper Automotive has slashed more than $2 million in costs and saved 100 jobs from layoff — all by reducing waste. Bob Cook, plant manager at the Scanlan Street auto parts manufacturer, hosted a lean manufacturing session at the plant yesterday where 10 manufacturers from different sectors learned first-hand how to cut waste, and what an impact it can have. “This is not about a reduction in the workforce, it is about reducing waste in the … Continue reading →

Posted in Economics, Lean thinking, Management, Systems thinking, UK | Tagged , , | 1 Comment

Lean Six Sigma Case Studies

Posted on February 27, 2008 by John Hunter

ValuMetrix Services provides some really nice lean six sigma case studies. Simple short but still with enough detail to actually provide some sense of what is going on. While on the topic of online case studies let me plug the Curious Cat management improvement library. I think it is one of the more valuable resources for management improvement offered on the Curious Cat sites. Library shelves: health care articles, lean manufacturing articles, six sigma articles, newly added articles… via: Daily … Continue reading →

Posted in curiouscat.com, Health care, Lean thinking, Management, Quality tools, Toyota Production System (TPS) | Tagged , , , | 1 Comment

Car Powered Using Compressed Air

Posted on February 25, 2008 by John Hunter

Jules Verne predicted cars would run on air. The Air Car is making that a reality. The car would be powered by compressed air. Certainly seem like an interesting idea. Air car ready for production: Refueling is simple and will only take a few minutes. That is, if you live nearby a gas station with custom air compressor units. The cost of a fill up is approximately $2.00. If a driver doesn’t have access to a compressor station, they will … Continue reading →

Posted in Fun, India, Innovation, Lean thinking, Management, Science, Toyota Production System (TPS) | Tagged , , , , , , , , , , , | 11 Comments

Toyota Presses On

Posted on February 24, 2008 by John Hunter

At Toyota, a Global Giant Reaches for Agility With plants in 27 countries, more new factories under construction and workers speaking languages that include Russian and Turkish, Toyota’s top executives are trying a difficult balancing act – replicating the company’s success and operating principles in other countries while ceding more control to these new outposts at the same time. … Next year, it expects to sell more than 10.4 million cars worldwide, double what it sold in 2000. … At … Continue reading →

Posted in Lean thinking, Management, Management Articles, Toyota Production System (TPS) | Tagged , , , , ,

Software Supporting Processes Not the Other Way Around

Posted on February 19, 2008 by John Hunter

Rental Car IT What was funny about that exercise were the looks we got from the no nonsense King of IT: “Of course, we want things to be simple and flexible — why are you bothering to tell us this?” Yet, in the next sentence, they are talking about spending 3 million dollars on a packaged application to help them with one small part of their business, rather than building it themselves (which we all thought would be cheaper but … Continue reading →

Posted in Data, IT, Lean thinking, Management, Software Development, Systems thinking | 10 Comments

Using Books to Ignite Improvement

Posted on February 7, 2008 by John Hunter

Recommended Reading From an Employee-Owned Company [the broken link has been removed] Soon after, another Web Industries employee picked up “Kanban Made Simple,” a guide for adopting Kanban, Toyota Motor Corp.’s just-in-time manufacturing process by John M. Gross and Kenneth R. McInnis. Within weeks, other employees were reading it. A group of machine operators used the book’s ideas to slash chronic late deliveries and improve scheduling processes. In the 18 months since Mr. Quarrey picked up “Ideas Are Free,” he’s … Continue reading →

Posted in Books, Lean thinking, Management | Tagged , , | 5 Comments

Creating Jobs

Posted on January 19, 2008 by John Hunter

Do Lean Companies Create Fewer Jobs? No, they create more. If you assume the lean company grows sales at the same rate as some poorly management company then it may well be that the lean company creates fewer jobs. However that is not a valid assumption. Deming provided the reason in his presentations to Japan in the 1950’s with his chain reaction. From page 3 of Out of the Crisis Improve Quality —> Costs decrease because of less rework, fewer … Continue reading →

Posted in Career, Deming, Economics, Lean thinking, Management, Popular, Systems thinking | Tagged , , , , | 5 Comments

The Power of a Checklist

Posted on December 7, 2007 by John Hunter

Great article on The Checklist – If something so simple can transform intensive care, what else can it do? by Atul Gawande A decade ago, Israeli scientists published a study in which engineers observed patient care in I.C.U.s for twenty-four-hour stretches. They found that the average patient required a hundred and seventy-eight individual actions per day, ranging from administering a drug to suctioning the lungs, and every one of them posed risks. Remarkably, the nurses and doctors were observed to … Continue reading →

Posted in Health care, Lean thinking, Management, Process improvement, Psychology, Quality tools | Tagged , , , , , | 4 Comments

Lean, Toyota and Deming for Software Development

Posted on December 2, 2007 by John Hunter

Mary Poppendieck on The Role of Leadership in Software Development, very nice 90 minute webcast: In this 90-minute talk from the Agile2007 conference, Lean software thought leader Mary Poppendieck reviewed 20th century management theories, including Toyota and Deming, and went on to talk about “the matrix problem”, alignment, waste cutting, planning and standards. She closed by addressing the role of measurement: “cash flow thinking” over “balance sheet thinking”. via, Leadership is not Obsolete for Self-Organizing Teams! Once again Mary provides … Continue reading →

Posted in Deming, IT, Lean thinking, Management, Software Development, Toyota Production System (TPS), webcast | Tagged , , , , , , , | 5 Comments

Arbitrary Rules Don’t Work

Posted on November 28, 2007 by John Hunter

Procedurally Enforcing Workflow by Michael Salamon: UI gem, and a great reminder for the RIAA/MPAA: You can’t force people to follow directions they deem arbitrary. I bet if that gate spit out $100 bills people would use it. Why matters. You can’t just expect people to act in a way that seems arbitrary. As I stated in Poka-Yoke Assembly, Do you Read Instructions Carefully Before Assembly? Nope, I don’t. I expect I can make a quick judgment if I really … Continue reading →

Posted in Lean thinking, Management, Popular, Process improvement, Psychology, Respect | Tagged , , | 1 Comment