1st Edition

The Toyota Kaizen Continuum A Practical Guide to Implementing Lean

By John Stewart Copyright 2011
    218 Pages 118 B/W Illustrations
    by Productivity Press

    218 Pages
    by Productivity Press

    Written by a recognized leader in the manufacturing industry with nearly two decades of experience working for Toyota, this book supplies a firsthand account of the realities behind implementing the Toyota Production System (TPS). The Toyota Kaizen Continuum: A Practical Guide to Implementing Lean presents authoritative insight on how to use the TPS to drive operational value and improvement across all segments of an organization.

    Highlighting valuable lessons learned directly from the TPS masters at the Toyota factories in Japan, John Stewart provides a time-tested approach for implementing a process of continuous improvement. Delving into his wide-ranging experience—that includes time as a team member on the assembly line and managing the vehicle assembly division for Toyota’s largest European operation in the United Kingdom—he explains how to get the process started, how to get senior management excited about the possibilities, and details a process for implementing the TPS in your organization.

    • Written by an industry veteran named one of the Top 10 Automotive Executives by Automotive News in 2007
    • Unveils the methods used within the walls of the world’s premier manufacturing organization
    • Illustrates valuable lessons learned with real-world examples of TPS implementations
    • Describes five simple steps for executing change in any organization

    The book includes case studies that illustrate real-life successes and failures behind the walls of the world’s largest automobile manufacturing organization. Detailing a five-step process for executing improvement initiatives, it supplies you with the tools and understanding of the core principles of the TPS needed to implement and sustain a culture of continuous improvement in your organization.

    Introduction
    Don’t Believe Everything That You Read in a Book
    ABC’s of TPS
    The Kaizen Continuum

    Foundational Elements of the Toyota Production System
    An Overview of the Toyota Production System
    Toyota’s Recent Turmoil
    A History of the Toyota Production System
    Kentucky Alchemy
    Keep It Simple
    The Toyota Production System versus Lean Manufacturing
    Standardization
         Quest for the Cube
         Visiting the Plant Floor
         Understanding Standardized Work
    Just In Time (JIT)
         The Pull System
         Flow Production
         Takt Time
    Jidoka
    Continuous Improvement (Kaizen)
    Developing the Tools

    Why the Toyota Production System Makes Sense: Common Sense
    Common Sense 101
    Understanding Value
    Understanding Demand
    Common Sense in Action

    Common Misconceptions and Misunderstandings Regarding the Toyota Production System
    TPS Misconceptions and Misunderstandings
    Which Way Is Best?
    Toyota Production System Historical Overview
    Kanban System Overview
    The Toyota Way
    The Customer Knows Best
    Go. See. Act

    Waste Management … Improving the Manufacturing Process One Kaizen at a Time
    Gap Management
    The Three M’s
         Muda
              Transportation
              Waiting
              Overstock
              Overproduction
              Repair
              Overprocessing
              Non-Value-Added Work 
         Muri
         Mura
    Classification of Muda
         Transportation
         Waiting
         Overstock
         Overproduction
         Repair
         Overprocessing
         Non-Value-Added Work
    Muda Countermeasure Methods
    Waste Elimination Example

    The Golden Rules of the Toyota Production System
    Fundamentals
    The Golden Rules of TPS
         Simplify
         Standardize
         Specialize
    Capital Investment Guidelines
         Tangible Return on Investment Period
         Recycle, Redeploy, and Reuse
         Simple, Safe, and Reliable

    Cost Management for Profitability
    Understanding the Death Spiral
    Understanding the Cost Structure
         Fixed and Variable Costs
         Minimum Variable Costs
         Break-Even Point
         Managing Costs
         Managing Cost Example

    Execution
    Facing Reality
    The Five-Step Process for Executing Improvement Initiatives
         Assessment: Understanding the Business
         Setting the Course
              Identify the Project Leader
              Completely Understand the Project Assessment
              Completely Understand the Project Target
              Identify the Project Resources
              Determine the Roles and Responsibilities
              Develop the Plan
              Completely Understand the Costs
              Communicate
              Execution
         Rapid Implementation
         Stabilization
         Continuous Improvement
    Conclusion

    Index

    Biography

    John Stewart is the operating partner for Monomoy Capital Partners, a New York-based private equity fund. At Monomoy, John is responsible for portfolio management. He has worked with numerous businesses of various sizes to increase their bottom line results. Prior to joining Monomoy, John worked for Toyota Motor Corporation for eighteen years. He started with Toyota on the shop floor and worked his way through each level of the organization until he found himself responsible for Toyota’s largest European manufacturing division. John was selected by Automotive News as one of the top young professionals in the automotive industry in 2007.