ABSTRACT

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 |3 pages

The Problem: Distance from Toyota

chapter |7 pages

The Predicament: Perplexing Failure

chapter |2 pages

The Position: Plant First

chapter |5 pages

The Purpose: Will and Skill

chapter |5 pages

The Plan: Hoshin Kanri

chapter |8 pages

The Property: Waste Elimination

chapter |9 pages

The Practice: Standard Work

chapter |12 pages

The Patois: 8-Step Problem-Solving

chapter |20 pages

The Pattern: Flow, Pull, and Heijunka

chapter |6 pages

The Path: The Toyota Template

chapter |6 pages

The Proof: TPS Results

chapter |2 pages

The Perceptions: Mental Images

chapter |2 pages

The Post Script: Personal Matters