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.
In July 2006, I pressed record on a conversation with Norm Bodek. The audio quality was poor. I had no idea what I was doing. Norman, who had spent decades going to Japan and had published Ohno and Shingo in…
Ford spends roughly $100,000 a year on each of its first-line production supervisors. The title on the job posting is “Process Coach” – language borrowed directly from Lean thinking. The role description talks about Sounds great, right? Online job board…
You know the feeling in the conference room when the team finally lands it. The fishbone is covered in sticky notes. You’ve worked through five whys, or ten, or fifteen. Somebody on the team traces the line with a finger…
Thanks, as always, to Ryan McCormack for this. He always shares so much good reading, listening, and viewing here! Subscribe to get these directly from Ryan via email. News, articles, books, podcasts, and videos about how to make the workplace…
Tesla builds cars in what used to be the NUMMI factory, a joint venture between Toyota and GM (which meant it was run as a Toyota plant with "Lean" practices). Before that, it was a dysfunctional GM plant. Now that it's a Tesla plant, did they learn from Toyota or does it seem more like "the old GM?"
Jamie Bonini described a person who looks like 25% overhead to a finance team — but without whom the entire Toyota Production System falls apart. Bonini is the vice president of Toyota’s Production System Support Center (TSSC), which has spent…
TL;DR: Organizations invest in teaching people to see problems and solve problems — but skip the middle step: making it safe and worthwhile to speak up about them. I’ve seen blank huddle boards in hospitals. Cards and markers sitting untouched.…
TL;DR: Fujio Cho explained that standardized work is not about control or compliance–it’s the foundation for learning, quality, and continuous improvement. When used as Toyota intended, standardized work creates stability, makes problems visible, and helps leaders improve systems rather than…
TL;DR: Deming and Toyota’s Fujio Cho asked the same uncomfortable question: why do management systems destroy motivation in people who started out wanting to do good work? The answer points to practices leaders can actually change. When leaders talk about…
This week’s Operational Excellence Mixtape tackles the challenge of sustaining improvement amidst turbulence and change fatigue. We explore why values must act as your “North Star” when markets shift, methods for building quality systems that fight entropy (with examples from…
TL;DR: In a 1993 speech, Toyota leader Fujio Cho said organizations can create their own Lean systems, but success depends on three principles: leaders going to the gemba, asking “why” to learn from problems, and respecting and motivating people —…
TL;DR: NUMMI proved in the 1980s what healthcare is still learning today: you can’t punish your way to safety. Real improvement comes from mutual trust, system thinking, and leaders who respond to problems with curiosity–not blame. When we talk about…
