TOYOTA WAY

The 14 Principles of the Toyota Way is a management philosophy used by the Toyota corporation that includes the Toyota Production System. The main ideas are to base management decisions on a "philosophical sense of purpose", to think long term, to have a process for solving problems, to add value to the organization by developing its people, and to recognize that continuously solving root problems drives organizational learning.

Acronym - CULTURE- Challenge, Understanding, Learning, Teamwork, Uniqueness, Respect and Empowerment / Engagement
*see page 14 principles of The Toyota Way for details

THE TOYOTA PRODUCTION SYSTEM

4 Goals of Toyota Production System:

1) Better ways to secure and ensure production quality
2) A working environment for maximum potential
3) Lowering costs by total "Elimination of Muda" (Waste)
4) Strong flexible company

A brief overview with Objectives:

Introduce building blocks of the TPS system

Topics to be covered include waste elimination, standards, Jidoka (ability to stop the line), Just-In-Time, Teamwork, Heijunka (line leveling), Kaizen, Flexibility an role of Team Members (employees)

Presentation will illustrate inter dependencies and interrelations between these concepts to form a strong cohesive and seamless program

Realize most important asset is your people who will be key in your company's success (affect safety, quality, kaizen, mutual support and respect for everyone in the company.

TPS is ... bringing problems to the surface so they can be fixed, thereby eliminating waste

STANDARDIZED WORK CHARTS (SWC)

Understand results without Standards in place

Benefits of having Standards in place - highlight bottlenecks and opportunities (Kaizen)

Provide a tool to give participants to develop SWCs within their organizations

JOB ELEMENT SHEETS (JES)

Foundation for Standardized Work

Develops a history of the process

A tool for training and problem investigation

Provides a standard for TPS Objectives

Tells the T./M.in the process, WHY we do it this way

FLOOR MANAGEMENT DEVELOPMENTAL SYSTEMS (FMDS)

Why Proactive vs. Reactive Management?

Provide "Tools" to manage a process, a line , an area , a department or a company

Examples include various zone control boards, andons, additional visual management systems

Start Simple & Grow from there

Daily management tools

What is the purpose of Zone Control and other Visual Management Systems.

Ability to gather and share information with the group

Ability to align group actions with Company Corporate achievements

Ability to utilize and sustain basic mgt. Foundation PDCA

Achievement of Key Performance Indicators (KPI's) through Kaizen, Problem Solving and QC Tools

5-S

This refers to the safe, clean, neat, and orderly arrangement of the workplace that provides a specific location for everything, eliminates anything not required, and supports the team member.

Introduction of 5 steps for the 5S program - visual management tool

JOB INSTRUCTION

Realize problems / benefits with / without proper training

Provide a proven approach to effective training

In class participation to practice / evaluate participants grasp of concepts

PRACTICAL PROBLEM SOLVING (PPS)

*Review impact of poor problem solving techniques

Class participation on exercises applying knowledge they have gained

*Introduction a of system to effectively solve problems using Root Cause Analysis

*Through actual hands on participation class can utilize their newly acquired skills by working on actual processes from your company

Additional Courses to support Core Training above

PDCA

A complete understanding of the PDCA cycle.

Be able to determine when and how to utilize PDCA

it is important to understand how and why PDCA evolved. The PDCA process helps us impacts the way you do your work

carry out the principles of the Toyota Production System. This module will help you see how this impacts the way you do your work

implement your new knowledge by participating in class with exercises and follow-up

KAIZEN CIRCLES

provide overview of purpose of circles

provide detailed advisor and circle leader training through classroom & hands on experiences

provide framework - 8 steps

provide reporting mechanisms - tools to complete

A3 REPORT WRITING

*Understanding WHY there is a need for this!

*Understand the process builds competencies important for your company’s success!

*Understand enough to start writing your own A3

JIDOKA

*One of the two main pillars of the Toyota Production System (the other is Just-In-Time).

Jidoka is a system which notifies us of problems with a process or equipment. It refers to the ability of team members to stop the line if they notice an abnormality

Recognize benefits through a presentation and provide examples

Note: Courses can be tailored to your needs