The Toyota Template the Plan for Just In Time and Culture Change Beyond Lean Tools 1st edition by Ledbetter 9781138578715 1351263706

ISBN 10: 1351263706

ISBN 13: 9781138578715

Author: Ledbetter

Much has been written about Toyota over the last 30 years focusing on both its products (superior vehicles), and its operational excellence based on its Toyota Production System (TPS). The Toyota Template details the critical concepts and methods that Taiichi Ohno implemented in developing the Toyota Production System. This book is different, however, regarding the parallels it draws between Toyota’s pre-TPS condition and companies today who are attempting to become more efficient and Lean. In view of efficiency, excellence, culture, and general “Leanness,” many organizations are in the same position as Toyota prior to implementing what was once called the “Ohno System.” The building of TPS, with the goal to eliminate waste, evolved as problems were encountered and solutions put in place. A wonderful byproduct of these years of work was the growth of a problem-solving culture throughout Toyota that is unique in the business world. Currently, the Toyota Production System is well established. Though constantly improving, the historical picture is visible. The question many have tried to answer for their own companies is “how can they achieve world class efficiency?” The Toyota Template answers this question. This book: Explains the critically important elements of the Toyota Production System. Analyzes the sequence of implementation as the system developed. Places these elements in a logical order of implementation based on the history and current knowledge. In addition, it addresses the effect of each element on the culture. The author was prompted to write this book because of his personal observations of the failure of most attempts to develop Lean systems. What makes Toyota stand out is not any of the individual elements – It is crucially important to have all the elements together as a system. Most attempts have been focused on bits and pieces of the elements, or the tools. The Toyota Template is about the relevance of the Toyota Production System to “any type of business” today. It is not an all-inclusive explanation of every aspect of TPS. Rather, this book succinctly identifies the key elements, places them in a logical, sequential order of implementation, and explains how each contributed to the formation of the Toyota culture.

Chapter 1 The Problem: Distance from Toyota

Endnote

Chapter 2 The Predicament: Perplexing Failure

Endnotes

Chapter 3 The Position: Plant First

Endnotes

Chapter 4 The Purpose: Will and Skill

Endnotes

Chapter 5 The Plan: Hoshin Kanri

KPI RULES

Measuring Overall Progress

Chapter 6 The Property: Waste Elimination

OHNO’S 7 WASTES

Overproduction

Waiting

Transportation

Over-Processing

Excessive Inventory

Unnecessary Motion

Defects

5S

Endnotes

Chapter 7 The Practice: Standard Work

TOTAL PRODUCTIVE MAINTENANCE (TPM) AND MACHINE BACK-UP: TENSION IN THE LINE

TEAMWORK: THE MULTI-SKILLED EMPLOYEE

Endnotes

Chapter 8 The Patois: 8-Step Problem-Solving

Endnotes

Chapter 9 The Pattern: Flow, Pull, and Heijunka

CONTINUOUS FLOW: ALIGNMENT OF PROCESSES IN THE ORDER OF VALUE ADDED

PULL: PACES AND PRIORITIZES PRODUCTION, AND PROMOTES PROBLEM-SOLVING

KANBAN: METERING FLOW

HEIJUNKA: PRODUCTION SMOOTHING

SINGLE-MINUTE EXCHANGE OF DIES (SMED): SET-UP TIME REDUCTION

EndNotes

Chapter 10 The Program: Jidoka, Quality at the Source

EndNotes

Chapter 11 The Path: The Toyota Template

WHEN SHOULD THE TEMPLATE BE IMPLEMENTED?

IN WHAT ORDER SHOULD THE TEMPLATE BE IMPLEMENTED?

EndNotes

Chapter 12 The Proof: TPS Results

ENVIRONMENT

EndNotes

Chapter 13 The Perceptions: Mental Images

EndNotes

Chapter 14 The Post Script: Personal Matters