Tag: Toyota

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.

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:

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.

This post builds off of a little rant I went on over on LinkedIn. I wrote: The Catch-22 of "Lean" training and "implementation"... Executives want big returns and high ROI. That's understandable. But, at the core of Lean, if you're going to call it that, is "#Kaizen," which means allowing everybody to do small improvements even if there isn't big ROI.

The first thing that prompted me to write this post is an interesting article about Toyota and their Georgetown, Kentucky plant that's known as TMMK (via Ward's Auto): "New Lexus Big Test for Toyota’s Georgetown Plant and Its New Manager" How does their approach and mindset seem to differ from Tesla?

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. 

Over the past month, there's been so much in the news about Tesla. This column from Joann Muller, who covers the auto industry for Forbes, caught my eye again recently: "Musk Thinks Tesla Will School Toyota On Lean Manufacturing; Fixing Model 3 Launch Would Be A Start" It's not a direct quote (I don't think) from CEO Elon Musk that they will "school" Toyota on Lean manufacturing. I'd suggest there's little evidence that Musk and Elon are even really trying Lean manufacturing as a strategy or a mindset. He's doing his own thing and will sink or swim accordingly.

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.

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.

Tomorrow, my post will be about headlines that scream about ratings for The Oscars being "down from last year" or "the lowest in X years." As I've blogged about before, I'm always skeptical of such simplistic comparisons that might mask the real underlying trend. But first, could the Academy avoid last year's embarrassing mixup?

Here's an interesting Bloomberg article about Toyota never being satisfied, which includes improving the way they improve: "Toyota's Way Changed the World's Factories. Now the Retool" Did you know that Toyota has a central TPS group??

I did manage to buy a book that was published by NUMMI to celebrate their 10th anniversary. "10 Years of Quality & Teamwork" is the title. Here is the cover and I'll share a few things that caught my attention inside. It's interesting to think through this book in the context of : Tesla (the current owners of the building - see my past blog post) Healthcare organizations