Tag Toyota

Toyota Thinking: Leadership, Systems, and Continuous Improvement

Toyota is often cited as the inspiration for Lean, but its success is rooted in leadership behaviors, management systems, and a deep commitment to learning—not tools or slogans. This archive brings together blog posts, podcasts, and reflections on Toyota’s approach to quality, continuous improvement, psychological safety, and respect for people. Many of these posts explore what leaders outside Toyota often misunderstand—and what truly matters if they hope to learn from Toyota rather than copy it.

How Toyota Uses TQM to Teach Quality to Japanese Hospital Doctors

Last week, I wrote about the influence of Total Quality Management (TQM) on Toyota -- in the past and the present, in Japan and beyond. Today, to follow up on that, I'm going to share some excerpts from some material that was shared by a Toyota leader who presented at a hospital I visited earlier this year as part of the Kaizen Institute-organized Japan trip.

TQM at Toyota and the Influence on Lean – Past and Present, Japan and U.S.

Toyota's TQM Activities for organizational vitality and continuous improvement in lean management.

I'm very excited to be leaving for Japan for another study trip in just over a month. This will be my second trip this year, this time with Honsha, after previous (and hopefully future) trips organized by Kaizen Institute.

Even though the previous tours have been focused on Toyota, as well as Lean and Kaizen in various organizations, one common thread is Total Quality Management, or TQM. In many Japanese organizations, TQM has been a solid foundation of practice for two or three decades, where it tended to be a fad here in the U.S., as I've blogged about:

Jess Orr on Lean Leadership, Toyota Lessons, and Saving 200 Jobs

My guest for Episode 311 is Jess Orr, a continuous improvement practitioner at WestRock, a large paper and packaging company, where she helps plants foster a culture of continuous improvement and employee engagement.

\Her experience includes working directly for Toyota Motor Manufacturing Kentucky. She is particularly passionate about sharing best practices across industries, which motivated her to found Yokoten Learning.

In today's episode, we talk about her path from Six Sigma Black Belt to a Lean-thinking engineer at Toyota. How did she progress from solving problems herself to developing others? We'll talk about a blog post that she wrote for this blog earlier this year, Lean and ROI, leadership and culture, and much more. What is it like working outside of Toyota again? I hope you enjoy the discussion.

You Can’t Cut Your Way to Success in Healthcare, with Andre DeMerchant

Joining me for Episode #307 of the podcast is my friend Andre DeMerchant, the President of DeMerchant Healthcare Solutions Inc., based in Kitchener, Ontario. We first crossed paths when we had the chance to work together with an American healthcare client via our then-affiliation with Pascal Dennis and Lean Pathways. 

In today's episode, we talk about Andre's history working for Toyota in Canada and what he learned there -- and why it's important that he learned about "how flow works" at Toyota. We chat about the terms "Lean" and "The Toyota Production System" and what those words mean to him. How does TPS "transcend culture and language," as well as industries?

We then shift to talking about healthcare and some of the common challenges, including "financial hardships," that are faced in many countries. Why are hospitals "poorly prepared for change" in many cases? Another main theme is "cost cutting" and why you can't cut your way to success. 

David Meier, Lessons and Wisdom From Working at Toyota and Teaching Others

Back on the podcast for the fifth time is my friend David Meier, a Lean / TPS consultant who is a former Toyota leader at their plant in Georgetown, Kentucky. He's gotten into what's, perhaps, the most Kentucky of industries... distilling bourbon (and more).

I'll have two more podcast episodes where David and I talk about bourbon, whiskey, and continuous improvement for almost 90 minutes total there. Those episodes are coming soon.

Today is a shorter episode, where we catch up and hear more about what David has been doing since his last podcast appearance in 2010 when we talked about the challenges Toyota was facing then. In this episode, David drops a lot of knowledge and wisdom in a very short time -- thoughts on problem solving and how Lean thinking isn't easy for anybody, even if you're Japanese.

Managers Must Help The People They Supervise

Last week, a nurse manager downloaded the free first chapter of my book Lean Hospitals and wrote this message in the contact form:

"Interested to see how the disconnect between management and the staff supervised can be helped. Too many managers refuse to help those they supervise. A growing number have never done the work that they are in charge of getting done. Patients and residents feel it, not healthy. Poor PR. It does get back to the consumer. Difficult to fix at that point."

In my experience working with many hospitals, her comments resonate with me. Identifying problems like these doesn't mean Lean provides easy solutions for organizational transformation.

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