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Toyota on the Lean Post
Tesla vs. TPS: Seeking the Soul in the New Machine
While Tesla has excited customers and drawn praise for innovative design and bold thinking, author Jeff Liker believes that it faces tough challenges in its approach to ramping up production that challenge its mechanistic vision of manufacturing.… More »
How do I love thee? Let me count the ways – on a Valentine’s Day A3
The question lean practitioners Tracy and Ernie Richardson get more than any other isn’t about problem-solving, takt time, standardization, or their book. It’s about their “lean” marriage.… More »
Thank you, Tatsuro Toyoda
John Shook remembers the late Tatsuro Toyoda, former president of Toyota.… More »
Shook Addresses Current State of Lean Thinking After U.S-Turkey Tiff Compels Keynote Countermeasure
Indefatigable presenter John Shook quickly made this video as a countermeasure to being denied entry to Turkey, where he was scheduled to keynote an Istanbul conference.… More »
How Team Leaders Should Divide Their Time
"Through my career, I’ve seen one group of individuals on the shop floor who need the most support and training – yet instead receive weak training and inconsistent support. They are 'team leaders,'" writes Andrew Quibell. In his new sketch and animation, Quibell lays out a time-tested, Toyota-inspired plan to help these essential team leaders hold their own in times of minimal support.… More »
A Deeper Dive into Visual Management at Toyota
"In a previous sketch I introduced Toyota’s approach to visual management, or Floor Management Display Systems (FMDS), including the six elements of creating FMDS," writes Andrew Quibell. "Now it’s time for a deeper dive into those six elements and explore how their approach guarantees an effective floor display will present compelling messages."… More »
An Overview of Visual Management at Toyota
"Implementing visual management (VM) is a cornerstone of any lean transformation," writes Andrew Quibell. "And few companies know that better than Toyota." In this first of two sketches on visual management at Toyota, Andrew illustrates the fundamentals of the process as Toyota practices itself and teaches its suppliers.… More »
Reflecting to Learn: Takeaways and Reflections on the A3 Process
In the wake of yesterday's interview with Mr. Isao Yoshino on the roots of the A3 process at Toyota, LEI Chairman and CEO John Shook shares more context about A3s and how they came to be.… More »
How the A3 Came to Be Toyota’s Go-To Management Process for Knowledge Work (intro by John Shook)
A3 thinking is synonymous with Toyota. Yet many often wonder how exactly this happened. Even if we know A3 thinking was created at Toyota, how did it become so firmly entrenched in the organization’s culture? Retired Toyota leader Mr. Isao Yoshino spearheaded a special program that made A3s Toyota’s foremost means of problem-solving. Read more.… More »
Raised by Toyota: A Question and Answer with Tracey and Ernie Richardson
In this extended interview, Toyota veterans Tracey and Ernie Richardson share how they learned at the source, explain how they apply their lessons widely (including their personal life), and speculate why this system called lean could just as well be called...our J-O-B.… More »
The Importance of Team Leaders on the Shop Floor
Why does upper management often fail to invest in team leaders on the shop floor? Andrew Quibell has his money on a lack of perspective. Check out his newest sketch on the critical importance of this key lean role and why there's no underestimating its function in a lean system.… More »
No Shortcuts: Creating a Lean Environment the Right Way
As much as we may wish there was a way to pull off a lean transformation with only a basic knowledge of its ideals, there isn't one. Michael Ballé explains why investing the time it takes to fully learn lean is worth every second you put into it. It may take a while, but the benefits will speak for themselves.… More »
Is There No Other Lean Exemplar Than Toyota?
"I believe that while Toyota isn’t the only lean exemplar out there," writes Michael Ballé, "it still gives us a flawless example of what lean truly is – a definition that is so often misunderstood. Let us try to disentangle the matter." Read more.… More »
TPS or the Toyota Way?
"Students of lean are often confused by the variety of ways Toyota explains the Toyota Production System," writes Michael Ballé. "For instance, 'what is the link,' they ask, 'between the TPS house and the Toyota Way?'" The answer in Michael's latest article for The Lean Post.… More »
Personal PDCA and How I Learned It
"In 23 years at Toyota, I had many assignments and different bosses, I managed many people," writes Mark Reich, "but a constant part of the culture was what I’ve come to call 'personal PDCA' – a kind of mentored self-development cycle." Read how Reich came to understand this principle himself and how he teaches it to others.… More »
Why Toyota is Still My North Star
"In the past five years the local lean engineering community has gained a deeper hands-on appreciation of how intermeshed product and processes are," writes Michael Ballé. "Product innovation often comes from progress in process innovation. We also understand better the truly outstanding feats of engineering that Toyota’s new drive represents."… More »
TPS 2.0?
Jim Morgan and Jeffrey Liker chime in on Toyota's announcement of their TNGA program (Toyota New Global Architecture). "The impetus for TNGA is not the recall crisis," they say, "but rather Toyota’s history, with a push added by the Great Recession... Toyota is constantly working on the next generation of fundamental product and process innovations and occasionally we get a snapshot." Read more.… More »
We're Ernie and Tracey Richardson: Ask Us Anything
It's our second "Ask Me Anything" post, this time with lean coaches Tracey and Ernie Richardson. With a combined 54 years of experience at Toyota, here's your chance to ask them questions on problem solving and all things capability development!… More »
Toyota on Lean.org
Leadership Q&A: Dr. Jack Billi, associate dean and associate vice president for medical affairs
From the LEI senior executive series on lean leadership: Jack Billi, M.D., associate dean for clinical affairs, University of Michigan Medical School, professor of Internal Medicine and Medical Educa… More »
Lean Beyond Production
Read how Lean Thinkers, using the same lean tools that worked in production, now are making improvements and benefits off the plant floor, in environments as diverse as an insurance company, academia,… More »
C.J. Buck, CEO of Buck Knives
When sales of a key product cratered, Buck Knives CEO C.J. Buck realized that he had to cut costs by 30% to stay in business. He moved the company from California to Idaho and lauched a lean transform… More »
What is the Theory of Constraints, and How Does it Compare to Lean Thinking?
Read about and discuss this topic.… More »
Lean Thinking: A Look Back and a Look Forward
The meaning of lean thinking, how lean got its name, and an example of how it improved a grinding process By LEI President Jim Womack.… More »
Follow-up Q&A to the Webinar: On the Mend - Changing a healthcare organizational culture to continuous improvement
The lean healthcare webinar “On the Mend: Changing a healthcare organizational culture to continuous improvement” drew an engaged audience that submitted hundreds of questions, many more than we cou… More »
Womack on Lean Management (DVD)
In this two-hour seminar recorded live, lean management thought leader James Womack explains how to manage and lead in a lean management system, the successor to obsolete “modern management” methods.… More »
Improvement Kata / Coaching Kata
What is a Kata? A kata is a pattern you practice to learn a skill and mindset. Through practice the pattern of a kata becomes second nature - done with little conscious attention - and readily avail… More »
Online - Introduction to Lean Thinking and Practice
This online course serves as an introduction to the key concepts, philosophies, and tools associated with lean thinking and practice. Designed through a joint effort between the Lean Enterprise Instit… More »
The Lean Manager
For many companies, the most important problem is not doing lean; it is becoming lean. How can they advance beyond realizing isolated gains from deploying lean tools, to fundamentally changing how the… More »
The Lean Manager (eBook)
An ebook version of The Lean Manager, by lean experts Michael and Freddy Ballé. The sequel to the Ballé’s international bestselling business novel The Gold Mine, The Lean Manager tells the compelling … More »
Gemba Walks, 2nd Edition (audiobook)
A collection of essays read aloud by author Jim Womack, based on the many gemba walks he has taken around the world. The 2nd edition contains 12 new essays, including thoughts on lean in healthcare an… More »
Why Toyota is Still My North Star
"In the past five years the local lean engineering community has gained a deeper hands-on appreciation of how intermeshed product and processes are," writes Michael Ballé. "Product innovation often comes from progress in process innovation. We also understand better the truly outstanding feats of engineering that Toyota’s new drive represents."… More »
TPS 2.0?
Jim Morgan and Jeffrey Liker chime in on Toyota's announcement of their TNGA program (Toyota New Global Architecture). "The impetus for TNGA is not the recall crisis," they say, "but rather Toyota’s history, with a push added by the Great Recession... Toyota is constantly working on the next generation of fundamental product and process innovations and occasionally we get a snapshot." Read more.… More »
We're Ernie and Tracey Richardson: Ask Us Anything
It's our second "Ask Me Anything" post, this time with lean coaches Tracey and Ernie Richardson. With a combined 54 years of experience at Toyota, here's your chance to ask them questions on problem solving and all things capability development!… More »
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