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Toyota Kaizen Methods : Six Steps to Improvement - Isao Kato

Toyota Kaizen Methods

Six Steps to Improvement

Paperback

Published: 30th November 2010
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Toyota Kaizen Methods: Six Steps to Improvement focuses on the skills and techniques practiced inside Toyota Motor Corporation during the past decades. This workbook focuses on the actual training course concepts and methods used by Toyota to develop employee skill level, a core element of Toyota's success. It is not a book about holding Western-style five-day Kaizen events, which were in reality quite rare during the development of Toyota's production system and are virtually nonexistent today inside Toyota. Written by two of Toyota's most revered and experienced trainers, the book -

  • Traces the origins of Kaizen since the inception of Toyota Motor Corporation
  • Articulates the basic six-step Kaizen improvement skills pattern taught inside Toyota
  • Helps practitioners of Kaizen improve their own skill level and confidence by simplifying concepts and removing any mystery in the process
  • Provides homework assignments and a wealth of forms for analyzing work processes

If you take the time to study the concepts detailed here, you will be reviewing the same methods and techniques that were harnessed by generations of Toyota supervisors, managers, and engineers. These techniques are not the secret ingredient of Lean manufacturing; however, mastery of these timeless techniques will improve your ability to conduct improvement in almost any setting and generate improvement results for your organization.

!What I personally learned from people like Isao Kato and Art Smalley during my Toyota years was that a company's success largely can be attributed to total employee involvement in daily Kaizen. This difference is critical when compared to traditional Western manufacturing companies. Team members in Toyota working with improvement tools, involvement opportunities, and a structured process constantly delivered amazing results that surpassed my expectations. This book represents a model for understanding Kaizen inside Toyota and the skills required to analyze basic processes and drive improvement. --Russ Scaffede, former V.P. of manufacturing, Toyota Motor Manufacturing

Introduction Background of Kaizen in Toyota History of Kaizen Methods in Toyota The Toyoda Precepts Training-Within-Industry Job Methods Introduction "P-Course" Introduction Development of Toyota's Kaizen Course Operations Management Consulting Division and Jishuken Events at Tier One Suppliers Summary Notes Introduction to Kaizen in Toyota The Importance of Kaizen Key Concepts Basic Pattern for Kaizen Note Step 1: Discover Improvement Potential Introduction Kaizen versus Problem Solving Kaizen Attitude Analytic Skills for Kaizen Opportunity Awareness Basic Methods for Uncovering Waste and Identifying Improvement Opportunities Summary of Step 1: Discover Improvement Potential Homework Assignment Note Step 2: Analyze Current Methods Introduction Basic Analysis Methods Summary Homework Assignment Notes Step 3: Generate Original Ideas Introduction Key Concepts Regarding Idea Generation Summary Homework Assignment Notes Step 4: Develop an Implementation Plan Introduction Key Concepts Summary Homework Exercise Step 5: Implement the Plan Introduction Key Concepts Summary Homework Exercise Step 6: Evaluate the New Method Introduction Key Concepts Summary Homework Exercise Summary Introduction Step 1: Discover the Improvement Potential Step 2: Analyze Current Methods Step 3: Generate Original Ideas Step 4: Develop an Implementation Plan Step 5: Implement the Plan Step 6: Evaluate the New Method Appendix 1: Ten Areas to Investigate for Operational Improvement A1.1 Improvement Possibilities for Work Motion A1.2 Focus on Variations in Work Element Time A1.3 Separate Human Work and Machine Work for Kaizen A1.4 Revise Standard Work in Process A1.5 Reduce Walking Distance A1.6 Work Balance between Operations A1.7 Quality Improvement Possibilities A1.8 Equipment Reliability Improvement Possibilities A1.9 Material Flow and Storage Improvement Possibilities A1.10 Other Improvement Areas Appendix 2: Forms and Instructions A2.1 Work Analysis Sheet A2.2 Therblig Motion Analysis Form A2.3 Time Study Form A2.4 Standardized Work Chart A2.5 Setup Reduction Analysis Form Index About the Author

ISBN: 9781439838532
ISBN-10: 1439838534
Audience: Professional
Format: Paperback
Language: English
Number Of Pages: 156
Published: 30th November 2010
Publisher: Taylor & Francis Inc
Country of Publication: US
Dimensions (cm): 27.9 x 21.6  x 1.27
Weight (kg): 0.45
Edition Number: 1