Category Archives: Toyota Production System (TPS)

People: Team Members or Costs

Posted on April 1, 2006 by John Hunter

Inside TPS at Toyota, Georgetown, Kentucky [the broken link was removed] by Ralph Rio: Toyota believes people need to be intimately involved with the process to understand how to improve it. The team member writes the standardized work they use because the person performing the work is the true expert. People are trusted to understand the process and improve it. Automation is used but is seen as a tool for helping people manage the process. This can be contrasted with … Continue reading →

Posted in Deming, Management, Systems thinking, Toyota Production System (TPS) | Tagged , , , , , , , | 4 Comments

What makes Toyota tick?

Posted on March 27, 2006 by John Hunter

Advanced Manufacturing magazine continues the focus on Toyota with a cover article, What Makes Toyota Tick? [the broken link was removed] by Vanessa Chris “Toyota has been coined ‘the most feared automaker in the industry.’” Just a few days ago I posted on: Fear Remains a Toyota Motivator. No matter what Toyota continues to be the focus of attention. Every aspect of the assembly process flows flawlessly into the next – making the plant’s 157 processes seem like one. Parts … Continue reading →

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

Fear Remains a Toyota Motivator

Posted on March 23, 2006 by John Hunter

First, don’t let the title fool you, this is not an indication Toyota is going against Deming’s obligation of management to “Drive out fear and build trust so that everyone can work effectively”. Deming was talking about driving out the fear management creates for employees intentionally (forced ranking…) and un-intentionally (creating a climate where people are more fearful of pointing out problems than just ignoring them…). See: Deming and Toyota. This article is talking about Toyota’s never ending quest to … Continue reading →

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

Deming and Toyota

Posted on March 17, 2006 by John Hunter

In response to Deming Electronic Network message, Deming and Toyota (broken link removed): I have read a few of the threads referring to Toyota and their success. I am somewhat familiar with the Toyota Production System (where Lean principles sprouted from), but I have often wondered if Toyota subscribed to all of Deming’s 14 points. I believe Toyota applied Deming’s ideas to create a management system and continued to develop that system to create the Toyota Production System (also known … Continue reading →

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Toyota in China: Full Speed Ahead

Posted on March 10, 2006 by John Hunter

Toyota in China: Full Speed Ahead [the broken link was removed], Business Week. Yoshimi Inaba, who’s driving the Japanese auto maker’s expansion in the Middle Kingdom, discusses the Chinese market and his goals there. Toyota’s market share is just 3.5% in China, compared to 13% in the U.S. and more than 40% at home in Japan. We’re a minor player in the China market, with a 3.5% share, but we’re one of the few manufacturers where demand exceeds supply. Even … Continue reading →

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

Manufacturing’s Influential Thinkers

Posted on February 26, 2006 by John Hunter

Manufacturing’s Influential Thinkers and Doers [the broken link was removed] by John S. McClenahen This article includes many of those I feel have contributed to the improvement of management over the last 35 years including: W. Edwards Deming, Taiichi Ohno, Shigeo Shingo, Gary Hamel and Eliyahu M. Goldratt. However, “the best manufacturing thinkers of the last several decades” are Taiichi Ohno and Shigeo Shingo, contends Mercer’s Slywotzky. Ohno was a Toyota Motor Co. vice president and Shingo a consultant. In … Continue reading →

Posted in Management Articles, Manufacturing, Toyota Production System (TPS)

Innovation at Toyota

Posted on February 24, 2006 by John Hunter

The Birth of the Prius by Alex Taylor III: By the end of 1993 the development team had determined that higher oil prices and a growing middle class around the world would require the new car to be both roomy and fuel-efficient. Other than that, they were given no guidance. “I was trying to come up with the future direction of the company,” says Watanabe, who headed corporate planning at the time. “I didn’t have a very specific idea about … Continue reading →

Posted in Innovation, Management, Systems thinking, Toyota Production System (TPS) | Tagged , , , | 4 Comments

Toyota Special Report: Thinking Production System

Posted on February 13, 2006 by John Hunter

Toyota Special Report: Thinking Production System [the broken link was removed]. A very interesting article on Toyota’s web site (www.toyota.co.jp). At the 2003 Automotive Parts System Solution Fair, held in Tokyo, June 18, 2003, Teruyuki Minoura, then-managing director of global purchasing, Toyota Motor Corporation, talked about his experiences with TPS (the Toyota Production System), and what it means for suppliers and for the future of the auto industry. This short article is peppered with many great quotes as section headers: … Continue reading →

Posted in Management, Quality tools, Respect, Systems thinking, Toyota Production System (TPS) | Tagged , , | 1 Comment

TPS – Take 2

Posted on January 25, 2006 by John Hunter

The cover story in latest issue of Industry Week focuses on what people have missed when applying ideas from the Toyota Production System. Learning From Toyota — Again [the broken link was removed] by John Teresko: “Why is it that the TPS tools of lean, agile, TQM, TPM, re-engineering, just-in-time, cellular/continuous workflow and so on — never seem to really pay off big [aside from Toyota]?” asks Michael Paris, president of Hinsdale, Ill.-based Paris:Consulting. His response: “Unless TPS is everywhere … Continue reading →

Posted in Deming, Lean thinking, Management, Quality tools, Toyota Production System (TPS) | Tagged , ,

Toyota’s Early History

Posted on January 22, 2006 by John Hunter

via Got Boondogle: A book that I recently finished is “Quest for the Dawn” by Shoji Kimoto. “Quest for the Dawn” is a fascinating true story set from about 1930 to the mid 1950s of a bold business quest to build an automobile from the ground up. The relentless inventors were Sakichi and Kiichiro Toyoda and, of course, the car manufacturer was the Toyota Motor Company. Look interesting, so I went on amazon.com and Quest for the Dawn by Shoji … Continue reading →

Posted in Books, Management, Toyota Production System (TPS) | Tagged , , | 4 Comments

Lean at NUMMI

Posted on January 11, 2006 by John Hunter

Lean at NUMMI (site broke the link so I removed it) by Patrick Waurzyniak , Manufacturing Engineering. An article well worth reading. NUMMI’s production system is patterned closely after TPS, which is constantly changing and being updated, notes Gonzalez-Beltran. The pillars of TPS are the waste-reduction techniques of Just-in-Time production, bringing inventory to where it is needed and at the right time, and also jidoka, which provides machines and operators the ability to detect abnormal conditions and immediately stop work … Continue reading →

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

TPS v. Lean Manufacturing

Posted on December 19, 2005 by John Hunter

Great article from Superfactory, TPS vs. Lean and the Law of Unintended Consequences [the broken link was removed] by Art Smalley: Real TPS is not just about “flow” or “pull production” or “cellular manufacturing” or any of the other catchy phrases or tools you may frequently hear. For over fifty years TPS in Toyota has been primarily concerned with making a profit, and satisfying the customer with the highest possible quality at the lowest cost in the shortest lead-time, while … Continue reading →

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

Planet Kaizen

Posted on December 18, 2005 by John Hunter

Toyota has a section on their web site called Planet Kaizen [the broken link to www.toyota.com/planetkaizen was removed, this is a rare instance where they are doing us a favor by removing this poorly designed application from the internet]: “what happens when you dig a little deeper and peel back the sheet metal to discover what makes a Toyota a Toyota.” It requires Flash to view Planet Kaizen. I think it has amazingly bad visual controls (as do many flash … Continue reading →

Posted in IT, Management, Toyota Production System (TPS) | Tagged , , , , , | 1 Comment

Toyota Production System in Indiana

Posted on November 29, 2005 by John Hunter

Photo by Daniel R. Patmore Via Evolving Excellence [the broken link was removed], Indiana plant president passes on lessons [newspaper also broke link so I removed it too]: Q. Is it different teaching the Toyota Production System to American team members than it is to teach it to Japanese? A. It’s not so different. Americans are eager to learn. American team members are more serious about job security, so their motivation is higher than that of the Japanese. The Japanese … Continue reading →

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Toyota Manufacturing Powerhouse

Posted on November 28, 2005 by John Hunter

Great required reading [the broken link was removed] via Evolving Excellence, Relentless [the broken link was removed], Detroit News: As Toyota expands rapidly, it is also grappling with a shortage of skilled managers and engineers. When it decided in June to build its seventh North American assembly plant in Woodstock, Ontario, officials said one reason they chose that site was because the new factory could be overseen by the team running its nearby Cambridge plant. Last month, the normally acquisition-shy … Continue reading →

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

Management Improvement Flavors

Posted on November 27, 2005 by John Hunter

Lean Manufacturing Visionary Jim Womack On Frontiers Of Lean Thinking [broken link has been removed], webcast and additional questions and answers: Question: For a firm seeking to improve — what comes first? Six Sigma quality or lean implementation? James Womack: Agh! These are all the same thing. You need to start with the value stream for every product, draw a map of its current state, and ask about each step: Is it valuable? Is it capable? Is it available? Is … Continue reading →

Posted in Deming, Lean thinking, Management, Popular, quote, Six sigma, Toyota Production System (TPS) | Tagged , , , , , , , | 6 Comments