Toyota by Toyota: Reflections from the Inside Leaders on the Techniques That Revolutionized the Industry

231 Pages·2012·8.897 MB·English

by  Samuel Obara, Darril Wilburn

Industrial & Manufacturing Engineering / Manufacturing & Processing O
b
a
What is our Purpose? Addressed honestly, this hard question triggers the necessary r
a
reflection on shortcomings and weaknesses that are the fuel for improvement. It is
•
a recurring theme in this volume. … Hansei, the Japanese word meaning humble W
and frank reflection, is another important concept in this book. Reflection, often
i
l
glossed over, is fundamental to TPS and the PDCA cycle. This book records the b
u
reflections of several Toyota veterans—reflections on how they learned TPS and
r
n
how they’ve applied the learning in companies around the world.
—Pascal Dennis, president of Lean Pathways Inc. and
Reflections from the Inside Leaders
Shingo Prize-winning author
T
Written by former Toyota associates, Toyota By Toyota: Reflections from the on the Techniques That
O
Inside Leaders on the Techniques That Revolutionized the Industry focuses
on the purpose of Lean methodologies, techniques, and principles. It compiles Revolutionized the Industry
Y
more than a century of combined experience from management-level employees
who supply little-known insights about the Toyota Production System (TPS)— O
featuring many who worked directly with Taiichi Ohno.
T
The book illustrates experiences at Toyota locations around the world, including
the United States, Brazil, Venezuela, Europe, and Japan. Associates from various A
divisions, including sales, training, logistics, manufacturing, and human resources,
provide diverse points of view regarding the application of the Lean principles
discussed. In each chapter, TPS experts: B
Y
• Share their story about when and how they learned the specific Lean

technique, methodology, or concept
T
• Describe the Lean technique, along with its benefits and pitfalls
• Supply helpful implementation tips O
A common thread that weaves these stories together is that the contributors had Y
to learn their lessons the hard way. Although there is no magical, painless way
O
to learn Lean, the authors hope that by sharing their experiences and struggles,
you can avoid having to struggle through the same lessons. Readers will benefit
from seeing the various approaches used to teach, as well as the unique way these T
Edited by
authors translate that learning to the reader.
A
Samuel Obara Darril Wilburn
K13796 and
ISBN: 978-1-4398-8075-3
90000
www.crcpress.com
9 781439 880753
www.productivitypress.com
K13796 cvr mech.indd 1 3/7/12 5:37 PM

TOYOTA
TOYOTA
by
Reflections from the Inside Leaders
on the Techniques That
Revolutionized the Industry
Edited by
Samuel Obara and Darril Wilburn
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2012 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20120308
International Standard Book Number-13: 978-1-4398-8076-0 (eBook - PDF)
This book contains information obtained from authentic and highly regarded sources. Reasonable
efforts have been made to publish reliable data and information, but the author and publisher cannot
assume responsibility for the validity of all materials or the consequences of their use. The authors and
publishers have attempted to trace the copyright holders of all material reproduced in this publication
and apologize to copyright holders if permission to publish in this form has not been obtained. If any
copyright material has not been acknowledged please write and let us know so we may rectify in any
future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced,
transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or
hereafter invented, including photocopying, microfilming, and recording, or in any information stor-
age or retrieval system, without written permission from the publishers.
For permission to photocopy or use material electronically from this work, please access www.copy-
right.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222
Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that pro-
vides licenses and registration for a variety of users. For organizations that have been granted a pho-
tocopy license by the CCC, a separate system of payment has been arranged.
Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are
used only for identification and explanation without intent to infringe.
Visit the Taylor & Francis Web site at
http://www.taylorandfrancis.com
and the CRC Press Web site at
http://www.crcpress.com
Contents
Foreword.................................................................................................ix
Introduction............................................................................................xi
About.the.Authors...............................................................................xiii
Chapter 1 Courage,.Humility,.Kaizen.................................................1
Darril Wilburn
The.Toyota.Way.2001...................................................................2
Courage,.Humility,.Kaizen.at.the.Heart...................................4
Teaching.Others..........................................................................14
Chapter 2 Stability.and.Standardized.Work.....................................21
Gerson Valentim Damiani
Importance.of.Standard.Work.................................................27
Why.Work.Using.Standards?..................................................28
Operational.Procedures,.Work.Instructions,.and.Work.
and.Labor.Procedures................................................................29
How.the.Work.Was.Done.at.Toyota:.Standard.Work.
before.Technology......................................................................31
How.Standard.Work.Was.Done.at.Toyota.after.the.
Introduction.of.Technology......................................................32
Factory.Layout........................................................................35
Objectives.of.the.Layout.......................................................37
Human.Factor........................................................................38
Problems.in.the.Implementation.of.Standard.Work.............39
Where.to.Place.Standard.Work.Instructions........................40
Chapter 3 Jidoka.................................................................................43
Renato Eiji Kitazuka, with Carlos Moretti
Origins........................................................................................43
Jidoka.as.a.Pillar.of.the.Toyota.Production.System..............44
So,.What.Is.the.Purpose.of.Using.Jidoka?..............................48
Using.Jidoka...........................................................................49
Implementation.Stages.of.Jidoka.........................................51
iii
iv  •  Contents
It.Was.Too.Early.....................................................................53
Conclusion..................................................................................54
Chapter 4 Just-In-Time.and.Kanban.................................................55
Carlos Yokio Fukamizu
Just-In-Time...............................................................................56
Introduction..........................................................................56
Introduction.of.Jidoka.and.Just-In-Time.as.the.Pillars.
of.TPS..........................................................................................56
Jidoka......................................................................................56
Just-In-Time.Manufacturing................................................57
Just-In-Time.(JIT).......................................................................58
Concept...................................................................................58
Total.Customer.Satisfaction.................................................59
More.Evident.Waste.in.the.Manufacturing......................60
Continuous.Flow.Process.(One-Piece.Flow).and.
Pull.System.............................................................................62
Lean.Methodologies.for.Waste.Elimination......................63
Examples............................................................................63
Kaizen.(Continuous.Improvement)....................................63
Kanban.as.a.Technique.of.JIT..................................................64
Conclusion...................................................................................69
Chapter 5 Problem-Solving.PDCA....................................................71
Sammy Obara
Definition.....................................................................................71
Why.Problem.Solving.Is.So.Important.along.a.Lean.
Transformation...........................................................................71
What.Is.PDCA?...........................................................................74
Do.You.Really.Need.a.Method?................................................74
How.and.Where.to.Find.Problems..........................................75
The.Mosquitoes.Case.................................................................76
How.Well.Do.You.Understand.the.Problem?.........................76
Genchi.Genbutsu:.The.Point.of.Cause.....................................77
How.Well.Can.You.State.the.Problem?...................................78
How.Well.Do.You.Understand.the.Causes?...........................81
Doing.Well.What.Does.Not.Need.to.Be.Done.................84
Project.Management..................................................................85
Contents  •  v
A.Quick.Note.on.Deadlines......................................................85
Standardization.........................................................................86
Recognition.................................................................................87
A.Higher.Level.of.Recognition................................................88
Yokoten:.Spreading.the.Learning.Laterally...........................90
What.Is.Next?..............................................................................91
Chapter 6 Toyota.Kaizen.Methods....................................................93
Art Smalley
Step.1:.Discover.Improvement.Potential..............................100
Step.2:.Analyze.the.Current.Method.....................................102
Step.3:.Generate.Original.Ideas..............................................105
Step.4:.Make.a.Kaizen.Plan.....................................................107
Step.5:.Implement.the.Plan.....................................................108
Step.6:.Verify.the.Results.........................................................109
Summary...................................................................................109
Chapter 7 Kaizen.Culture:.
The.Continuous.Improvement.Engine...........................111
Stephen J. Ansuini
The.Key.Elements.of.a.Kaizen.Culture..................................112
Visible.Sponsorship.and.Support.by.Management.........112
Leadership.Support.........................................................113
Clear.Purpose.and.Aligned.Goals.....................................115
Evolving.Continuous.Improvement.System....................117
Phase.1:.Introduction—Participation.Emphasis........117
Phase.2:.Transition—Participant.Development........120
Phase.3:.Process.Maturation........................................122
Summary..................................................................................124
Chapter 8 Elimination.of.Waste.in.Product.Design......................127
Patrick Muller
Value.Engineering/Value.Analysis........................................127
Waste.in.Process.Design.....................................................127
Waste.in.Product.Design...................................................128
Toyota’s.Purchasing.Philosophy........................................129
Fair.Competition.Based.on.an.Open-Door.Policy.....130
vi  •  Contents
Mutual.Prosperity.Based.on.Mutual.Trust.................130
Abide.by.the.Law.............................................................131
Toyota’s.Purchasing.Practices............................................131
Cost.Breakdown..............................................................131
Target.Costing,.VE/VA,.Kaizen....................................132
Value.Engineering/Value.Analysis..................................134
History.............................................................................134
At.Toyota,.Suppliers.Challenges..................................134
VE/VA.and.FMEA..........................................................135
VE/VA.and.Marketing...................................................135
Practical.Example...........................................................136
Chapter 9 Adapting.Lean.for.Made-to-Order/High-Mix,.
Low-Volume.Organizations............................................137
Greg Lane
OSKKK.to.Learn.and.Transform...........................................139
Learning.the.Processes.before.Managing.Them..................140
Constraints.Require.More.than.Quick.Fixes.......................141
Process.Focused,.Not.Product.Focused................................143
Segregating.Parts.to.Manage.Differently..............................146
Managing.in.Real-Time.Necessitates.Other.Lean.
Principles...................................................................................149
Proportionally.More.Indirect.Costs.Necessitate.
Lean.Accounting......................................................................152
Failures.......................................................................................155
Summary...................................................................................156
Chapter 10 Lean.Logistics..................................................................159
Robert Martichenko
Part.1:.Purpose.+.People.........................................................159
Introduction.........................................................................159
Purpose.................................................................................160
Customer.and.3PL.Collaboration......................................161
People.and.Planning............................................................162
Part.2:.Process...........................................................................163
Logistics.Route.Design........................................................163
Pull.Replenishment.............................................................164
Contents  •  vii
Velocity.and.Understanding.the.Importance.
of.Lead-Time.Reduction.....................................................165
Driving.Velocity...................................................................168
Manufacturing.Plant.Integration......................................169
Leveled.Flow.........................................................................170
Trailer.Yard.Layout.and.Visual.Management.................172
Quality.at.the.Source.and.Discipline.of.Process.............173
Lessons.Learned.and.Conclusion...........................................174
Chapter 11 Leading.a.Kaizen.Culture...............................................177
Bob Plummer
A.TPS.Symphony......................................................................178
Discovering.the.Kaizen.Culture.............................................179
Creating.and.Sustaining.the.Kaizen.Culture.
in.American.Factories.............................................................182
Implementing.TPS.Methods...................................................185
Back.to.the.Beginning..............................................................187
Leaving.GM...............................................................................188
Chapter 12 Hoshin.Kanri...................................................................189
Alistair Norval, with Darril Wilburn
What.Is.Hoshin.Kanri?...........................................................190
Why.We.Need.a.Strategic.Planning.System.........................191
What.Does.This.Result.In?......................................................192
Countermeasure.to.Strategic.Planning.Problems................192
Hoshin.Kanri.Enables.Organizations.to.Develop.
Strategic.Plans.That.Are..........................................................192
True.North................................................................................193
Tree.of.Focused.Activity..........................................................194
Plan,.Do,.Check,.Act.(PDCA).................................................196
Management.Process...............................................................199
Catchball...................................................................................200
Key.Thinker...............................................................................201
A3................................................................................................201
The.Power.of.Hoshin...............................................................203
Summary..................................................................................205