Toyota Kaizen Methods: Six Steps to Improvement, 1st Edition (Paperback) book cover

Toyota Kaizen Methods

Six Steps to Improvement, 1st Edition

By Isao Kato, Art Smalley

Productivity Press

154 pages | 105 B/W Illus.

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Paperback: 9781439838532
pub: 2010-10-19
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pub: 2017-07-26
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Description

Toyota Kaizen Methods: Six Steps to Improvement focuses on the skills and techniques practiced inside Toyota Motor Corporation during the past decades. This workbook focuses on the actual training course concepts and methods used by Toyota to develop employee skill level, a core element of Toyota’s success. It is not a book about holding Western-style five-day Kaizen events, which were in reality quite rare during the development of Toyota’s production system and are virtually nonexistent today inside Toyota. Written by two of Toyota’s most revered and experienced trainers, the book —

  • Traces the origins of Kaizen since the inception of Toyota Motor Corporation
  • Articulates the basic six-step Kaizen improvement skills pattern taught inside Toyota
  • Helps practitioners of Kaizen improve their own skill level and confidence by simplifying concepts and removing any mystery in the process
  • Provides homework assignments and a wealth of forms for analyzing work processes

If you take the time to study the concepts detailed here, you will be reviewing the same methods and techniques that were harnessed by generations of Toyota supervisors, managers, and engineers. These techniques are not the secret ingredient of Lean manufacturing; however, mastery of these timeless techniques will improve your ability to conduct improvement in almost any setting and generate improvement results for your organization.

Reviews

…What I personally learned from people like Isao Kato and Art Smalley during my Toyota years was that a company’s success largely can be attributed to total employee involvement in daily Kaizen. This difference is critical when compared to traditional Western manufacturing companies. Team members in Toyota working with improvement tools, involvement opportunities, and a structured process constantly delivered amazing results that surpassed my expectations. This book represents a model for understanding Kaizen inside Toyota and the skills required to analyze basic processes and drive improvement.

—Russ Scaffede, former V.P. of manufacturing, Toyota Motor Manufacturing

Table of Contents

Introduction

Background of Kaizen in Toyota

History of Kaizen Methods in Toyota

The Toyoda Precepts

Training-Within-Industry Job Methods Introduction

"P-Course" Introduction

Development of Toyota’s Kaizen Course

Operations Management Consulting Division and Jishuken Events at Tier One Suppliers

Summary

Notes

Introduction to Kaizen in Toyota

The Importance of Kaizen

Key Concepts

Basic Pattern for Kaizen

Note

Step 1: Discover Improvement Potential

Introduction

Kaizen versus Problem Solving

Kaizen Attitude

Analytic Skills for Kaizen

Opportunity Awareness

Basic Methods for Uncovering Waste and Identifying Improvement Opportunities

Summary of Step 1: Discover Improvement Potential

Homework Assignment

Note

Step 2: Analyze Current Methods

Introduction

Basic Analysis Methods

Summary

Homework Assignment

Notes

Step 3: Generate Original Ideas

Introduction

Key Concepts Regarding Idea Generation

Summary

Homework Assignment

Notes

Step 4: Develop an Implementation Plan

Introduction

Key Concepts

Summary

Homework Exercise

Step 5: Implement the Plan

Introduction

Key Concepts

Summary

Homework Exercise

Step 6: Evaluate the New Method

Introduction

Key Concepts

Summary

Homework Exercise

Summary

Introduction

Step 1: Discover the Improvement Potential

Step 2: Analyze Current Methods

Step 3: Generate Original Ideas

Step 4: Develop an Implementation Plan

Step 5: Implement the Plan

Step 6: Evaluate the New Method

Appendix 1: Ten Areas to Investigate for Operational Improvement

A1.1 Improvement Possibilities for Work Motion

A1.2 Focus on Variations in Work Element Time

A1.3 Separate Human Work and Machine Work for Kaizen

A1.4 Revise Standard Work in Process

A1.5 Reduce Walking Distance

A1.6 Work Balance between Operations

A1.7 Quality Improvement Possibilities

A1.8 Equipment Reliability Improvement Possibilities

A1.9 Material Flow and Storage Improvement Possibilities

A1.10 Other Improvement Areas

Appendix 2: Forms and Instructions

A2.1 Work Analysis Sheet

A2.2 Therblig Motion Analysis Form

A2.3 Time Study Form

A2.4 Standardized Work Chart

A2.5 Setup Reduction Analysis Form

Index

About the Author

About the Authors

Art Smalley worked for Toyota in Japan, before becoming the director of lean for a large US company and a consulting lean expert for McKinsey & Company.

Isao Kato spent 35 years with Toyota in a variety of management positions in manufacturing, HR, training and development, and supplier development.

Subject Categories

BISAC Subject Codes/Headings:
BUS053000
BUSINESS & ECONOMICS / Quality Control
TEC020000
TECHNOLOGY & ENGINEERING / Manufacturing