Lean or the Toyota way

Origins of Lean

At the origin of Lean, there is the family business of TOYODA and their desire for industrial simplification.

Sakichi Toyoda sought to ease the burdens of her mother who worked on the looms. Her innovations have not only improved her mother's working comfort but also her efficiency and productivity.

A century later, the success of the Toyota company has been built on the application of these basics which have not changed. Lean or the "Toyota Way" has established itself not only in the vast majority of industries, but is also breaking through in other sectors such as services, banks, hospitals, etc.

Liker - Toyota way

 

The 5 values ​​of the Toyota Way

 

1. Respect for people

Toyota's Lean puts people at the center. Communication must be open and sincere in a spirit of trust and mutual responsibility.

2. Teamwork

The challenge is to maximize the strength of the team and make a collective commitment to the education and development of everyone.

3. The Challenge

The company needs a vision and long-term perspective, Toyota's Lean seeks to nurture this spirit of Challenge.

4. Kaizen

The innovative approach at all levels of the organization is implemented thanks to very structured Lean systems. Lean promotes the learning organization.

5. Genchi Genbutsu

Improvements are made by consensus and close to the shopfloor in order to have everyone's commitment to their implementation. The goal is to achieve a complete success at the first go.

 

Lean applies to all levels of the company

 

The Toyota Way is based on a growth strategy that absorbs labor productivity gains and thus avoid layoffs. This success, which is its own, Toyota applies it on several levels:

  • Vision as the starting point for any change. An ambitious vision carried with perseverance, trial-and-error to ensure good interpersonal skills.

  • The role of management is to make life easier for employees at work while improving productivity. An organization based on the participatory mode.

  • Production management based on the speed of flow management through the TPS (Toyota Production System) and its 2 pillars which are Jidoka and Just-in-time.

  • The management of quality ensures through numerous standards, through the training of operators (production or quality), through the use of Poka-Yoke ... an excellent quality for Toyota's products today.

  • Lean Engineering improves the development of products and processes. Toyota's performance owes it as much to the development of their products and processes as to its production excellence.

  • Partnering with suppliers is a long-term partnership. Toyota not only protects its suppliers, but also makes them progress so that they reach the expected levels of quality and performance.

 

This article is obviously not exhaustive on everything that makes the strength of Lean at Toyota. It nevertheless allows one to realize that each action undertaken is far from being the result of chance or a unilateral decision, this culture is in their DNA and carried by the entire hierarchy on a daily basis.

 

Implementation with Marris Consulting

 

We start by performing a quick, approximately two-day performance diagnosis of your business, our goal is to identify the constraint, or to confirm your suspicions.

 

Once the constraint has been identified, we train the production teams in the Theory of Constraints and Lean principles, then we support these teams in improving performance.

 


Some videos about Lean

 

Reynald Debaut-Henocque, ex-VP of Toyota Motor Manufacturing France, gives his point of view on Lean and the industry in short videos.

Toyota key success factors only available in French

 


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About Marris Consulting

Marris Consulting is an industry consulting and training company specialized in the Theory of Constraints (ToC) and Critical Chain Project Management. We focus on improving the performance of manufacturing and process industries by using Constraints Management combined with Lean and Six Sigma. To boost project performance, we also use Critical Chain Project Management (CCPM), which we sometimes combine with Lean Engineering. Our 2-day performance audits, our performance consulting services and our project management, Lean & ToC training by our industry consultants offer a wide range of solutions to help our clients around the world reach the highest possible levels of performance.

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