I have been wondering where this tool actually comes from. In the introduction to Learning to See, Mike Rother describes it as a minor tool known within Toyota as “Material and Information Flow” mapping. I have many books about TPS in English and Japanese, of vintages ranging from 1978 to 2009. They contain all sorts of […]
Alan Weir is the Director of Production Operations at Toyota Motor Manufacturing UK. In this episode, Ryan Tierney and Matthew Thompson from Lean Made Simple ask him about: Working his way up from the shop floor to the level of leadership he’s in today What “Genchi Genbutsu” is and why it mat
Toyota's job rotations, in different forms, affect both daily work on the shopfloor and professional careers.
[...]
Other companies have had rotation programs for professional employees and operate their own “universities.” What is special to TPS is the rotations on the shop floor. They develop multi-skilled operators, track their achievements in skills matrices posted in the team areas, and conduct career planning, all through the HR department.
What is also special is the enthusiasm with which beneficiaries of that system reminisce about it. Tracey Richardson, for one, feels that no university at that time could have provided her with the knowledge and skills she acquired through Toyota. [...]
Within the quality profession, a capable process is one with a high CpkCpk. In the field, it is not quite so simple. My colleague Joerg Muenzing recently shared concerns about the process capability indices:
“Many manufacturers that I know struggle with incapable processes. Intellectually, people understand the concept of capability, but are unable to effectively apply it to an entire process. A single-figure measure for the entire chain would be ideal to better understand and manage it. The challenge is that the chain consists of processes with measurable characteristics, like thickness, substitute characteristics, like leak current to infer dryness, and also visual inspection results like blemishes or scratches....
This is an extract from our Good Lean Bad Lean online training by our expert teachers, Reynald Debaut-Henocque (ex-VP of Production of Toyota Manufacturing France) and Philip Marris. In this short video, Reynald explains what is the first Toyota Production System's basic skill according to Akio Toyoda, Toyota's President: all the managers should go to the shopfloor and study the processes.
All about lean manufacturing to help industry users to eliminate waste, and to improve efficiency, quality, flexibility and speed. [...] Regular posts look deeper in selected topics, and often offer a view different from mainstream, but based on the expensive experience of the main author. The author Prof. Roser has over twenty years of experience in industry, including 5 years at Toyota in Japan.
Listen to this episode from No Way Out on Spotify. Dave Snowden is the creator of the Cynefin Framework and originated the design of SenseMaker®, the world’s first distributed ethnography tool. He is the lead author of ....
All organizations, from families to nations to societies, have policies. [...] Policies tell us how to act or behave under a certain set of conditions. [...] The policies that most of us are familiar with are usually written and generally widely known. [...] But policies can also be unwritten practices, customs, or etiquette. [...] Policies, whether formal or informal, provide stability and a sense of security for the members of an organization—the comfort of the familiar, a sense of security and predictability. People know what to expect, today and tomorrow.
You are Doing It Wrong: Decision Making in the 21st Century
Simplicity reigns supreme in the realm of the Theory of Constraints (TOC). You set a single, unambiguous goal [...] The objective could be as straightforward as making money, or making money could be a prerequisite condition leading up to the actual goal. Either way, an organization must make money, so every organization with a purpose must make money, or at least enough, to pursue its purpose. [...] Cost Accounting has been the go-to model for making such pivotal financial decisions. [...] Cost Accounting: At its core, Cost Accounting is a system designed to ascertain the cost of specific products or services. Its primary purpose? [...] So, why do companies adhere to Cost Accounting? If you ask some accounting people, it's because
This in-person training in Paris is in French and co-hosted by an ex-VP of Production of Toyota Motor Manufacturing France and Philip Marris TOC and Lean expert.
Le Lean par Toyota. Reynald Debaut-Henocque, ex-VP Manufacturing de Toyota France et Philip Marris, DG de Marris Consulting animeront une formation en « présentiel » le jeudi 25 novembre 2021 à la Tour Montparnasse à Paris.
Deming’s Journey to Profound Knowledge by John Willis and Derek Lewis is the story of how W. Edwards Deming’s background, education and experiences inspired him to develop his System of Profound Knowledge. The book is sort of a biography, but very focused on those elements that led him to be the im
In the past, Marris Consulting have had the opportunity to organise a 6-day workshop led by William (Bill) Dettmer, the international expert on the Logical Thinking Process (LTP). We are pleased to announce that we will organise the 6-day LTP workshop in June 2024 in Paris. This time, it will be led by the LTP expert and Bill Dettmer's partner, Thorsteinn Siglaugsson. In recent years, Thorsteinn Siglaugsson has conducted several training sessions and coaching sessions alongside Bill. ...
Learning from the Past, Present, and Future to Drive Profits to New Levels: Roadmaps for Solving and Preventing Problems, Making Better Decisions, and Implementing the Ultimate Improvement Cycle by Bob Sproull.
The content of this book is centered around three seemingly diverse themes. [...] The final theme in this book is how to successfully implement the Theory of Constraints, and then combine Lean Manufacturing, Six Sigma, and the Theory of Constraints. The Theory of Constraints should be considered the "missing link" in most improvement initiatives. The author presents, in detail, why combining the Theory of Constraints with Lean and Six Sigma and all of the associated improvement tools and techniques will take your company to new levels of profitability. He introduces two new roadmaps. One roadmap is on how to implement the Theory of Constraints, while the other new roadmap is how to implement my Ultimate Improvement Cycle.
Philip Marris's insight:
This is Bob Sproull's tenth book. Others include the bestseller "Epiphanized" about TOC + Lean + Six Sigma.
If I were to ask most people what the connection between Porsche and Toyota is, they’d be confused. After all, there’s a big difference between a 911 and a Corolla. The German and Japanese automakers on the surface are about as different as bratwurst and sushi. But, Porsche likely owes its continued existence to Toyota.
Back in the 1990s Porsche was in deep financial trouble. Profits had dropped through the basement, from a surplus of $258 million to being in the red by over $180 million in the span of just six years. That’s hard to believe today, considering Porsche has one of the fattest profit margins in the auto industry. It wasn’t always that way, thanks to gross inefficiencies inside Porsche. ...
We all stand on the shoulders of those who have gone before. One of those giants was Freddy Ballé, who passed away on the31st of October. He was one of the first people in Europe to understand the significance of the Toyota Production System while he was working at Renault in the 1970s. He went to Japan on annual pilgrimages to seek answers to his questions about TPS from leading senseis at Toyota.
He used this learning to build the Valeo ProductionSystem. Early on, Toyota told me that only two suppliers in Europe really understood TPS - Freddy Ballé at Valeo and Peter Marks at Robert Bosch. Freddy went on to develop similar Production and Product Development systems at Sommer Allibert and Faurecia.
One of the best things I have done was to convince Jim Womack to publish the first lean novels by Freddy and his sonMichael. The Gold Mine, The Lean Manager, and Lead withRespect showed a global audience the thinking and behaviors that made a lean system work.
[...] Please note that there is a significant difference in the number of ideas generated. While in the USA, there is a measly 0.16 ideas generated by employee and year, in Japan it is a whopping 18.5 ideas per employee and year [...] in Europe there were only 0.4 suggestions per employee and year. [...] the adoption rate in Japan is 90%, significantly higher than the 38% in the USA, and 74% of employees generate ideas in Japan, whereas only 11% do so in the USA. The USA, however, pays better for ideas, with in average USD $458 per idea, where in Japan it is a measly USD $3.88. Money clearly is NOT the motivator for idea generation. [...] the net savings in Japan is USD $3250 per employee and year, almost ten times as much as in the USA with only USD $334 of savings. The reason for these differences [...] is that Toyota actually has the manpower to implement even smaller ideas, whereas in the Western world all such maintenance and support people have long since been axed to the minimum.
"Today’s manufacturing systems have become more automated, data-driven, and sophisticated than ever before. Visit any modern shop floor and you’ll find a plethora of IT systems, HMIs, PLC data streams, machine controllers, engineering support, and other digital initiatives, all vying to improve manufacturing quality and efficiencies.
Learn how to use the Theory of Constraints to generate growth, decrease your production cycles and accelerate the Lean program in your factory! You will get access to the videos during 12 months upon purchase.
The TOC Innovation Summit, the event that celebrates the transformative and innovative power of the Theory of Constraints (TOC) across diverse industries and sectors worldwide. Taking place from October 8-11, 2023 at the Margaritaville Beach Resort in Hollywood (near Miami), Florida, USA, this four-day in-person conference promises an immersive experience like no other. Our dynamic event will delve into the cutting-edge applications of TOC in industry, government, healthcare, education, and the ever-evolving advancements of TOC's body of knowledge.
Learn about the Lean Leadership Learning Tour, a transformative experience that will redefine success for your organization. [...] Discover a unique opportunity with the Lean Enterprise Institute (LEI) and Toyota Supplier Support Center (TSSC) for a transformative experience that will redefine success for your organization. [...]Lean Leadership Learning Tour scheduled for November 14-16, 2023. Get a sneak peek into the tour’s highlights, including behind-the-scenes experiences at Toyota Motor Manufacturing and GE Appliances. And gain insights into leadership and essential tools for success. Discover how this tour can be the catalyst for your lean transformation journey.
All about lean manufacturing to help industry users to eliminate waste, and to improve efficiency, quality, flexibility and speed. Topics include [...] manufacturing, logistics and operation. [...] Frequent topics include bottleneck detection and management, analysis of Toyota, in-depth analysis of lean tools, practical tips for the shop floor, and many more. Regular posts look deeper in selected topics, and often offer a view different from mainstream, ...
Balancing the need of high material availability with low inventory is tricky. Pull systems are a very good way to achieve this. But sometimes people argue with me that planning can be better if you use all the available information to create a production plan which then outperforms a pull system. In theory, this could work, but in practice it rarely does. After all, that is what conventional push systems are trying to achieve, usually with mediocre results. Let's have a look.
Did you like the bestselling novel “The Goal” by Eliyahu Goldratt? Philip Marris will present how you implement the ideas in the book to factories today. How to combine TOC and Lean to get the best of both worlds. A summary of his +30 years of experience of implementing TOC + Lean + Six Sigma in +300 factories all around the world and in all types of industry. Among others: ArcelorMittal, Ariane Group, Autoliv, Bayer, Bosch, Bulgari, Constellium, Embraer, GSK, Infineon, French Air and Space Force, Jaeger LeCoultre, Louis Vuitton, McDonald's, Procter & Gamble, Rolex, Safran, Siemens, SKF, Société Générale, Thales, & Veolia.
This webinar will also be the opportunity to announce and describe Marris Consulting’s new online and on-demand training “TOC in Production” service. (the “Good Lean Bad Lean” online training is already available here: https://e-learning.marris-consulting.com/ )
The webinar will end with a questions and answers session.
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