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I think Toyota, even with the problems, is a fantastic example of a very well managed company. Yet even with all the study of lean manufacturing even basic ideas are overlooked. For example, the two main pillars of the Toyota way are "continuous improvement" and "respect for people." For all of us, it is valuable to refocusing on core principles. We are too often looking for the next new idea.

When I worked at Toyota, I was instructed to memorize the company's 10 Attitudes. Even now that I have moved on to another company, I find myself drawn to these core values. The following examines which each of these Attitudes means to me personally.

The last reason this works at Toyota is because of the roles and skills of the people. Front-line workers know the true meaning and value of each standard procedure - not only in theory. They have the skills and knowledge to solve problems and an end-to-end process perspective. The supervisors are pivotal in developing these competencies. They check and confirm that the standard procedures have been put in place and that workers are following them exactly. Supervisors can improve processes through coaching, questioning (not ordering), and making front-line workers think and take responsibility. Managers (supervisors, managers, directors, and above) motivate workers by meeting with them to communicate the corporate vision.

A principle that has been often discussed (and hopefully practiced) in the Lean community over the past few years is usually described as "respect for people." A certain British rabble rouser recently said at a Lean conference "all this respect for people stuff is horse sh*t," and that it is a "conventional Western management interpretation." He mocked the idea of "respect for people programs," although I'm not sure where such a standalone program has ever been attempted.

A client and fellow lean learner today shared a cool extension of the Toyota Kata model for establishing target conditions

Kanban, which was originally modeled after a Toyota Production System, means "billboard" or "signboard" in Japanese. Scheduling systems like Kanban help to eliminate wasted resources, help people make more efficient use of their time, build stronger and more robust businesses, and improve current designs. This way, future businesses are able to reap the reward of previous experiences, solutions, and expertise. 

The answer to why Kanban is so effective in helping people and businesses DO THINGS BETTER actually has more than one part. We'll be listing a few of these parts below.

During one of my training opportunities a Toyota Sensei once told me that the highest form of "respect for people" was allowing people to solve their own problems.  This statement stuck with me and I have often used this during training/coaching sessions.  Apparently, this statement also stuck with my friend.  In the hallway last week he said after a year of gemba he finally understood his role as a leader and what I meant when I talked about "respect for people."   He said at first he loved the Lean approach, because he loved being in gemba, but after a while the follow-up became overwhelming to him and frustrating to the teams he worked with.  He said each time he went to gemba he felt guilty about the increasing number of problems he was not having the time to solve.

"Challenge" is one of the explicit values in The Toyota Way 2001 but it looks quite different. Yes, there are challenges issued. But behind that challenge is a support structure. The leaders, at all levels are expected to stretch their own personal development, but to do so within the context of kaizen, deep understanding gained by genchi genbutsu, team work and most important of all, respect. The leader's development level is gauged by how the challenge is met even more than whether it is met. Just "get-r-done" doesn't work here.

Too often [kaizen] has come to mean assembling a special team for a project using lean of Six Sigma methods, or perhaps organizing a kaizen "event" for a week to make a burst of changes. We sometimes hear the phrase "doing a kaizen" as if it were a one-off activity. At Toyota, kaizen […] is how the company operates at the most fundamental level.

Toyota is famously credited for living by their "we don't build cars, we build people" motto but in fact this same sentiment can be traced back nearly a century ago to the Reverend Samuel Marquis, head of the Ford Motor Company's employee relations department, when he said: "Mr. Ford shoots about fifteen hundred cars out of the back door of his factory every day just to get rid of them. They are the by-products of his real business, which is the making of men."

Excellent quote!

Get out there, go to the Gemba. I say this to executives and to people on-the-floor alike. They must start their Lean journey with a trip to see what Toyota calls the three reals - the real place, the real data and the real problem. They must go and see for themselves, not just take the advice of a Lean committee!

Below are the 10 main ideas Wakamatsu claims Taiichi Ohno lived by: Wastes hide, so start by disclosing all of your mistakes Discover the truth beyond your understanding Increasing production while limiting the number of workers is the only way to gain true success Act on problems right away and do not procastinate Don't feel satisfied by saying "I finished the job"; go beyond that and say "I can do more" Add "Appropriate Timing" to "Appropriate Method" in problem solving Believe in "I can" and question "I can't" The key to achieving progress is to never give up Don't do work at an average pace; the shortest way is always the easiest Change yourself first, if you want to change someone else

Wastes hide, so start by disclosing all of your mistakes Love it! Act on problems right away and do not procrastinate Great! The key to achieving progress is to never give up Yes! Don't do work at an average pace; the shortest way is always the easiest Amazing! Change yourself first, if you want to change someone else Timeless!

I wonder what it would take to segregate our inventory as Smalley does in the Toyota graphic?

Toyota has an average 14 mistake-proofing devices at EVERY workstation. You should, too! Go ahead and take away the opportunity to make a judgment error, an identification error, an entry error - the list goes on forever.

I agree - it is a must read

Good article on Toyota Business Practice.

Why wouldn't the team follow the new procedure since there are such clear benefits?  You probably have a theory or two if this experience sounds familiar to you.  The Toyota Way Fieldbook states that when people deviate from the original plan, it's a strong indication that there is a flaw in the plan.  This was also one of the main points of Implementing Change - Get It Done! There are reasons why people are not following a new procedure.  You need to find out what those reasons are and figure out what to do about it. Sustaining the improvements can be the most difficult part of the change process.

"Determination of root causes should provide a clear and obvious understanding of the necessary solutions." - Jeffrey Liker and David Meier, The Toyota Way Field book

The practical problem solving steps… 1. It is too early to talk about solutions. 2. It is still too early to talk about solutions. 3. It is still too early to talk about solutions. 4. It is still too early to talk about solutions. 5. Did someone mention countermeasures? 6. It is still too early to talk about solutions. 7. It is still too early to talk about solutions. 8. Yes, now we can talk about solutions.

Truly brilliant!!!