1st Edition

Toyota Kaizen Methods Six Steps to Improvement

By Isao Kato, Art Smalley Copyright 2010
    154 Pages 105 B/W Illustrations
    by Productivity Press

    154 Pages
    by Productivity Press

    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.

    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

    Biography

    Isao Kato

     …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