Tuesday, December 20, 2005

Anyother Cool Book - The Toyota Way

The Toyota Way

What does the customer really really want – defines value
Define Waste – 8 ways – all equally important:
  • Overproduction
  • Waiting (time on hand)
  • Unnecessary transport
  • Over processing / Incorrect processing
  • Excess inventory
  • Unnecessary movement in the process of completing the work
  • Defects in manufacture – repair / rework costs
  • Unused employee creativity

Principles:

  • Long term philosophy vs short term goals (Mission – contribute to country economy, well being of stakeholders, and Toyotas growth)
  • With the right process the results will follow – trust it
  • Continuous process flow to bring problems to the surface (link operations together)
  • Use pull systems to avoid over production
  • Level out work load (production control and management people) - heijunka
  • Culture of stopping to fix problems to get quality right the first time -Judoka ( and Quality – Jidoka)
  • Standardise tasks are the basis for continuous improvement and employee empowerment – balance rigid procedures vs challenge to improve
  • Visual control so problems not hidden – Just in time information
  • Use only reliable tested technology
  • Grow leaders who understand the philosophy
  • Develop exceptional people that will follow the philosophy
  • Learn by doing
  • Go and see for yourself (GENCHI GENBUTSU -)
  • Make decisions slowly by consensus - Implement Rapidly - Nemawashi – a technique is employed to reduce misunderstanding
  • Become a learning organisation through relentless reflection (Hansei) and continuous improvement (CI can only work with stable and standardised processes) –and KAIZEN

Flow
  • ID customer and added value
  • Separate repetitive from unique processes
  • Map flow – value add and no value add
  • Future state value stream map
  • Learn by doing (Plan do act)

Personal Leanings

  • Balance standardisation with individual autonomy – Currently more standardization would create greater efficiency and quality.
  • Standardisation is a Core and Key base for CI – without it there is no CI
  • Take the time get it right
  • How to principles become common?


Web links:

http://www.fredharriman.com/services/glossary/jidoka.html
http://www.strategosinc.com/jidoka.htm
http://www.thinkingmanagers.com/management/gemba.php
http://en.wikipedia.org/wiki/Nemawashi
http://www.si.umich.edu/

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