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The Sixth Sigma: Achieve Breakthrough Performance Using Six Sigma

Wednesday, March 12, 2008

Toyota Kaizen Way Improves Customer Service

Toyota exec shares insights on Toyota and its kaizen principles. ...

... "Our customer service philosophy is fix it right the first time and to have lifelong customers. The term kaizen is one of the pillars of the Toyota way. " ...


Via The Augusta Chronicle: Toyota exec

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Monday, March 03, 2008

Toyota Kaizen Carries Through to Motorsports

Toyota uses kaizen techniques to coordinate continuous improvement across its motorsports teams. The teams have confronted major challenges with this mindset. The knowledge of new race teams is leveraged across the organization. ...

Toyota kaizen mindset permeates the motorsports organization

... "Kaizen, a Japanese term commonly translated as continuous improvement, has been the ethos for Toyota's Motorsports operation. The way kaizen is achieved by the various teams in all three levels of NASCAR racing is by working together as one as much as possible. " ...


Via FOX Sports: NASCAR

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Wednesday, December 26, 2007

Toyota Kaizen Works in Vietnam

Kaizen principles can be successfully deployed anywhere in the world. Toyota replicates its success in Vietnam. ...

... "Regular kaizen (innovation) and optimization of all resources, especially supplying networks, have helped TMV provide customers with good products and services at reasonable prices. " ...


Via Saigon Times: Toyota Vietnam

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Tuesday, June 05, 2007

Toyota Recognizes Kaizen Suppliers

J.B. Hunt is recognized by Toyota as its Large Carrier of the Year for 2006. ...

JBHunt recognized for its kaizen methods by Toyota

... "In addition, Toyota scores each carrier on its ability to embrace and culturally implement Kaizen, Toyota's methodology for continuous improvement. J.B. Hunt has taken significant steps to eliminate waste from its own operations and further improve Toyota's supply chain processes by ensuring the production facilities receive the right amount of product at the right time. This is accomplished by utilizing a unique blend of intermodal and traditional truckload movements that provide Toyota with an on-time percentage greater than 99%. " ...


Via Toyota: Toyota Recognizes J.B. Hunt Transport Services, Inc. with the Prestigious 2006 Large Carrier of the Year Award

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Wednesday, December 27, 2006

Toyota Kaizen Poised to Eclipse GM

Toyota, built on a foundation of kaizen, is set to eclipse GM based on its business plan forecast for 2007. ...

... "Toyota's rise also would prove a victory of sorts for its unique corporate culture, the so-called Toyota Way, which is rooted in an obsession with craftsmanship and constant improvement, or kaizen. " ...


Via St Louis Today: Business

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Tuesday, November 21, 2006

Toyota Kaizen Culture: Texas Style

Toyota Texas plant builds new Tundra truck with kaizen culture ...

Toyota builds Tundra with kaizen efficiency in Texas

... "Reminders of the automaker's culture of kaizen -- or continuous improvement -- are everywhere as workers with Team Texas badges run slow-speed test production of the Tundra ... " ...


Via Reuters UK: Link

Greater San Antonio Chamber of Commerce info on Toyota Texas Plant ...

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Sunday, October 29, 2006

Kaizen Toyota Corolla Dependabiity ...

Toyota Corolla's dependability is a result of relentless focus on continuous improvement through kaizen. ...

Toyota Corolla's success is driven by kaizen ...

... "Every process -- from assembly operations to the paint shop, from bringing in parts to loading finished cars on trucks or trains -- has been refined. Toyota calls it kaizen, or continuous improvement. " ...


Via SanJose Mercury: The bestselling car ever

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Thursday, September 28, 2006

Kaizen System: Perform to the Next Level ...

The lean kaizen approach to continuous improvement is just what the doctor ordered to enable an organization to achieve the next level of performance. Article discusses the successful formula applied by Toyota and other manufacturing companies, that can translate to organizations in other industries. ...

... "Based on Kaizen, which means continuous improvement, it is a systematic approach to identifying and eliminating waste. " ...

Via American Venture Magazine: When you are on the Plateau ...

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Friday, September 22, 2006

Kaizen Delivery Improvement Recognized by Toyota ...

Toyota recognizes the Hub Group for reducing its variability in on-time delivery. Hub's achievement in delivery improvement is celebrated by Toyota with its Kaizen Challenge Award. The two companies worked collaboratively to enable this accomplishment. ...

Toyota partner leverages kaizen process for successful on-time delivery performance ...

... "Hub Group, Inc. has been awarded Toyota's prestigious North American Parts Operations (NAPO) 2006 Kaizen Challenge Award. Kaizen is a critical component of the Toyota Production System (TPS) management practice, and this award recognizes Hub Group not only for its ability to work in partnership with Toyota management, but for significant performance and efficiency improvements achieved in product deliveries to Toyota's U.S. Parts Delivery Centers (PDCs) across the country.

The kaizen team, comprised of both Hub Group and Toyota professionals, was able to significantly reduce bunching (the tendency for inbound container volumes arriving at PDCs to fluctuate unevenly throughout the week), improve on-time performance (from not-late to not-late and not-early), and to reduce costs by eliminating rail detention and storage for the Toyota PDCs. As a result of the success of this initiative, additional Toyota PDCs have been added to the program. Since Kaizen is a continuing process, further improvements will be explored and documented throughout Toyota’s PDC system. " ...


Via Hub Group: Hub Group Earns Toyota 2006 Kaizen Challenge Award

Hub Group, Inc. is a leading asset-light freight transportation management company providing comprehensive intermodal, truckload brokerage and logistics services.

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Thursday, September 14, 2006

Kaizen: Sony Toyota Quality Problems

Revered for their kaizen quality programs, Toyota and Sony suffer from quality problems ...

... "For a time, American and European executives flocked here to learn Japanese quality-control concepts like kaizen, or improvement. " ...

Via International Herald Tribune: Recalls by Toyota and Sony shock Japan's pride ...

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Saturday, August 19, 2006

Toyota Kaizen Cultural Strength ...

Toyota's culture enables its kaizen success ...

Kaizen at Toyota is strengthened by its culture ...

... "Some of its strengths are cultural ones shared by the best Japanese companies. These include a respect for lifelong learning that aids kaizen, or continuous improvement. In addition, a consensus management style, combined with a Confucian respect for hierarchy, allows the rapid implementation of decisions. " ...

Toyota Kaizen Cultural Strength: Via Autoweek: The Roots of Toyota's Strength ...

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Wednesday, July 19, 2006

Toyota Kaizen Obeya Room ...

Delphi Corporation and The Furukawa Electric Company collaborate to support Toyota's R&D and manufacturing divisions with a new facility, local staff, and a kaizen strategy for success. ...

Toyota kaizen strategy supported by supplier joint venture ...

... "The facility allows for greater flexibility in creating a tailored product for Toyota, which is strengthened by close contact and coordination. The facility also has an Obeya room where a cross-functional team can come together to solve problems quickly as part of Toyota's Kaizen approach to project management. " ...

Toyota Kaizen Obeya Room: Via Delphi: Delphi Furukawa Opens Customer Service Center in Ann Arbor ...

Definition of Obeya room ...

Via Lean Product Development from TBM Consulting Group - The Process: "Obeya: Big room – bringing all the people into one room to make critical decisions. "

The Toyota Way: Via Wikipedia, the free encyclopedia: "They are no more obvious than in the project room, or obeya where concise charts show the state of the project."

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Sunday, June 11, 2006

Lean 5S Tool Upgraded ...

Lean tool ...
Lean Toolkit upgraded ...

... "Kaizen Products LLC released its 5S ActionPack product upgrade. Designed to serve those getting started in Toyota Production System methods, the $349.00 multi-media training kit is now available. The 5S principles are a fundamental tool of the Toyota Production System, recognized world wide as a model of operational excellence. The 5S practice of Sort, Straighten, Sweep, Standardize and Self-Discipline are essential to establishing and maintain safety, quality, on-time delivery and productivity in any workplace. " ...

Lean 5S Tool Upgraded: Kaizen Products Releases 5S ActionPack Upgrade – Designed for the Lean Manufacturing DIY Market, New Version Contains Quick Reference Guides, Wallet Cards and Red Tags ...

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Thursday, June 01, 2006

Toyota Kaizen Improvement Leads in Stamping Labor Productivity ...

Toyota kaizen methods differentiate its performance in the industry ...
Toyota kaizen process allows its to maintain leadership in productivity measures, according to recent Harbour Consulting report North American automaker performance. ...

... "Toyota again led in stamping labor productivity, although its 1.42 stamping hours per vehicle degraded 3.6% from 2004. Toyota regained the lead in press productivity with a record 792 average parts per hour. Harbour uses a stamping index that weighs each of several measures in a process that creates a composite score of stamping productivity. On that basis, Toyota's Cambridge stamping shop ranked first, followed by Toyota Georgetown, Honda East Liberty, Honda Marysville and Toyota Princeton. Of the 10 best stamping plants, Toyota had three; Honda, two; DaimlerChrysler, Ford, General Motors, Nissan and NUMMI, one each. In total stamping labor productivity Nissan ranked third, behind CAMI, with 2.11 HPV. Chrysler Group was fifth (behind NUMMI), improving 6.7% to 2.64 HPV. As in assembly, Toyota is among the best in the industry, said Harbour. It is not a matter of spending more than competitors. It reflects regular kaizen improvement activities and the flexibility that comes with well coordinated engineering and manufacturing. Ford has also shown a renewed commitment to upgrade its stamping technology after several years of limited investment, and its performance is showing a steady climb despite aging equipment. " ...

Via Harbour Consulting: PRODUCTIVITY GAP AMONG NORTH AMERICAN AUTOMAKERS NARROWS IN HARBOUR REPORT 2006 (PDF) ...

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Wednesday, April 26, 2006

Toyota Kaizen Supplier Awards ...

CHD Meridian is recognized for kaizen supplier performance by Toyota. ...

... "A supplier for nearly seven years, CHD Meridian was honored by TMMK with the Supplier Kaizen Award for continuous improvement. Meridian provides TMMK team members with on-site health care, occupational health, acute and emergency care and oversees the operation of our pharmacy. Meridian recently participated in a practical kaizen activity in which they completed a standardized work assessment for all health centers at TMMK. " ...
Toyota recognizes suppliers for kaizen performance ...
Toyota Kaizen Supplier Awards: Via TMMK Toyota Georgetown: Toyota Motor Manufacturing, Kentucky Honors Ten Suppliers: Seven Suppliers from Kentucky ...

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Monday, April 24, 2006

Kaizen Improvement: Toyota Prius Project ...

Toyota kaizen at the heart of the Prius project ...

... "In many ways, the Prius project appears to be a textbook example of Toyota's much-vaunted, much-imitated internal management system and its mantra of kaizen, or continuous improvement, in which top executives steadily ratchet up performance standards for their employees, while also listening closely to suggestions and emphasizing consensus. " ...

Kaizen Improvement: Toyota Prius Project: Via Scripps Howard: Successful gamble with Prius fuels Toyota's trendsetter image ...

Kaizen principles drive the Toyota Prius project ...

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Wednesday, April 19, 2006

Kaizen Energy Efficiency Plan ...

Kaizen enables energy efficiency plan ...

... "This not only saves time, it also gives the energy plan instant credibility. As examples, Toyota uses its Kaizen-based continuous improvement process. " ...

Kaizen Energy Efficiency Plan: Energy Expert: A sound energy business plan: Via Plant Services ...

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Monday, April 17, 2006

Kaizen Pursuit Continuous Improvement ...

Toyota's foundation is kaizen, the pursuit of continuous improvement ...

... "Toyota's principles are reflected in the production methods it made famous, such as kaizen, or continuous pursuit of improvement, which means workers on the ground are entrusted and empowered to figure out better ways of making cars and fixing problems on the line. " ...

Kaizen Pursuit Continuous Improvement: Toyota workers learn knack of auto production in new global push: Via MSN-Mainichi Daily News ...

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Monday, April 03, 2006

Kaizen: Toyota Idea Bank ...

Toyota leverages kaizen process to fill its idea bank for implementation of continuous improvement opportunities. ...

... "Toyota also brought to the wider business world the concept of kaizen or continuous improvement, which puts a duty on every employee to contribute ideas on how the production process can be made better. " ...

Kaizen: Toyota Idea Bank: Via Times Online: Toyota powers to the front ...

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Sunday, March 05, 2006

Kaizen Worker Lean Manufacturing System ...

Workers adopt kaizen principles and leverage in the lean manufacturing system. ...

... "San Pedro helped eliminate that tough weld by bringing in a robot to do the job. His focus on safety is part of the Toyota Production System at the Fremont plant. The so-called lean manufacturing system uses Japanese terms and culture to emphasize worker protection and efficiency in building cars.
San Pedro calls himself a kaizen worker ... " ...

Kaizen Worker Lean Manufacturing System: Via Alameda Times-Star: NUMMI always a step ahead when it comes to workers' health ...

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Wednesday, February 22, 2006

Kaizen Improves Safety Performance ...

Great article on the application of kaizen to the improvement of safety performance. Christopher D. Chapman educates us on kaizen. ...

... "Kaizen, a systematic approach and problem-solving tool adopted from the Toyota Production System (TPS), is aimed at quickly implementing low-cost improvements that result in measurable impact. It can be used to enhance your safety program effectiveness exponentially. While kaizen traditionally and primarily has focused on production and efficiency numbers, it can effectively be shifted to improving safety and ergonomics.
" ...


Kaizen Improves Safety Performance: Via Occupational Hazards: Using Kaizen to Improve Safety and Ergonomics ...

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Sunday, February 19, 2006

Kaizen Right Even in Good Times per Toyota ...

Toyota emphasizes kaizen even in good times ...

... "There is no end to kaizen (improvement) even if the business performance is very favorable, said a Toyota executive. " ...

Kaizen Right Even in Good Times per Toyota: Cost cuts Toyota's top priority

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Kaizen Improvement Theme ...

... "The center will have facilities that feature Toyota's management theme kaizen, which means improvement, Chigara told reporters at the company's annual media conference yesterday ... " ...

Kaizen Improvement Theme: Via The Korea Herald: Toyota aims to sell 6,500 Lexus cars ...

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Toyota Kaizen Techniques at Production Center ...

Kaizen techniques are the cornerstone of Toyota production center ...

... "The North American Production Support Center is aimed at fostering skilled factory workers, who are capable of adequately supervising and managing the process of production with its techniques on production efficiency, such as kaizen. " ...

Toyota Kaizen Techniques at Production Center: Toyota Opens Kentucky Ouput Center: Via Motor Trend News

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Sunday, February 12, 2006

SixSigma Efficiency Model in the British Automotive Industry ...

Terry Murden explores the methods of Stuart Ross, a veteran of Six Sigma and Kaizen ...

... "Toyota claims to have developed the principles after the war and Nissan adopted them, introducing the concept of minimum waste and maximum efficiency to its new plant in Sunderland in the 1980s at a time when the British car industry was plagued with over-manning and underperformance. Kaizen and lean manufacturing are similar in concept, while Six Sigma, another efficiency model is driven more by technical improvements. " ...

SixSigma Efficiency Model in the British Automotive Industry: Via Scotsman Business: The man who would save Scottish industry ...

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Saturday, January 14, 2006

Kaizen Continuous Progress: Sakichi Toyoda ...

Formula 1 racing rules constrain innovation on new models. Toyota announces its Formula 1 model and utilizes the continuous improvement process of kaizen to produce new Formula 1 cars. Lessons are learned and incorporated into the design of subsequent models. Article explores the challenges of Formula 1 car design and the convergence on the kaizen method of improvement to innovate. ...

... "The Japanese say that this is part of the Toyota philosophy of continuous progress - known as kaizen - which has been part of the company's traditions since Sakichi Toyoda watched his mother and grandmother weaving cloth by hand and invented a series of weaving machines which not only speeded up the process enormously but eventually stopped automatically if the threads broke. " ...

Kaizen Continuous Progress: Sakichi Toyoda: Via GrandPrix: The shape of things to come?

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Wednesday, December 28, 2005

Kaizen: Lean Staffing Techniques

In a competitive market, kaizen and lean staffing techniques can be a competitive edge. Marla Dickerson explores the techniques of cola maker Ajegroup who know how to compete in the marketplace. ...

... "Lean staffing is another cost-cutting tool. Spokesman Paredes said the company's modern equipment, coupled with so-called kaizen, or continuous improvement, techniques, have helped it reduce the number of workers on each of the Huejotzingo plant's seven production lines to eight, which he says is fewer than half that of a typical bottling facility. " ...

Kaizen: Lean Staffing Techniques: In Mexico, Taking Fizz Out of the Cola Giants - Via Los Angeles Times

Additional resources on lean staffing techniques:

Kaizen Rapid Process | Lean Thinking | Lean and the Environment | Via EPA: "Kaizen, or rapid improvement processes, often is considered to be the building block of all lean production methods. Kaizen focuses on eliminating waste, improving productivity, and achieving sustained continual improvement in targeted activities and processes of an organization. Lean production is founded on the idea of kaizen or continual improvement. This philosophy implies that small, incremental changes routinely applied and sustained over a long period result in significant improvements. "

Feature Article - Building Better Powertrains Through Lean Approaches at Toyota: "The addition of three machinists known as the 'kaizen team' swells the ranks to a grand total of 17. And this kind of lean staffing exists throughout TMMWV. Toyota can operate in this mode because of a single-minded pursuit of the lean practices of the Toyota Production System (TPS). "

Via OnDemandJournal: "There is no greater roadblock to continuous improvement than a person who is fighting to keep a job that's not needed, especially if he's in a management role. Since small businesses already have lean staffing, that's less likely to be a problem. "

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Monday, November 28, 2005

Kaizen Mindset: Higher Targets ...

Seizo Okamoto, Toyota Motor Corp exec, provides his perspective on the Toyota Production System, TPS, and the challenge of creating the kaizen mindset through higher targets. ...

Kaizen Mindset: Higher Targets: Via American International Automobile Dealers: Indiana plant president passes on lessons ...

... "What's the most difficult aspect of the Toyota Production System to grasp? A. Kaizen -- it's not easy to maintain continuous improvement. You have to motivate [people] to have the kaizen mind-set. Then management has to give them higher targets, and then higher targets. " ...

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Toyota Kaizen: Enterprise DNA ...

The Panasonic Toyota Racing team embraces the kaizen method, which is part of the Toyota enteprise DNA. ...

Toyota Kaizen: Enterprise DNA: Via Auto Racing Daily: Panasonic Toyota Racing - Panasonic Toyota Racing set to test TF106 in Barcelona ...

... "Toyota in More Ways The TF106 is a natural evolution of its predecessor and an embodiment of Kaizen (continuous improvement), which forms an integral part of the global Toyota DNA. " ...

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Sunday, November 27, 2005

Kaizen: Heart of the Toyota Production System ...

Toyota Motor Corp. continues its push in automotive leadership, leveraging kaizen methods. ...

Kaizen: Heart of the Toyota Production System: Via Detroit News: Relentless-Toyota is poised to overtake GM, but here's the scariest part: Now it's stepping on the gas.

... "At the heart of the renowned Toyota Production System are two principles: kaizen, or continuous improvement, and respect for people. U.S. automakers first saw the system in action after Toyota formed a manufacturing venture in California with GM in 1984. " ...

Toyota kaizen methods are a competitive advantage in the automotive industry ...

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Tuesday, November 22, 2005

Kaizen Team Wins Competition ...

Kaizen Team Wins Competition: Via Surface Mount Technology (SMT): Toyota Philosophy Being Adapted to Electronics Industry

... "Armed with spreadsheets and PowerPoint presentations - and with the war whoop kaizen! - they claimed victory. And they took home a $10,000 grand prize. " ...

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Kaizen Necessary But Not Sufficient at Delphi ...

Delphi's kaizen and lean manufacturing implementation was necessary, but not sufficient to keep it out of bankruptcy. Kevin Farley explores the Delphi bankruptcy situation and the strides made by the company in its lean enterprise transformation. ...

Kaizen Necessary But Not Sufficient at Delphi: Via Bangkok Post: Even Lean wasn't enough at Delphi

... "Delphi retained the very best ex-Toyota sensei, pursued kaizen with a vengeance, and took out billions of dollars of operating costs. " ...

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Sunday, November 13, 2005

Kaizen Events: Positive Impact on Internal Process ...

Through the use of kaizen events, TG Fluid Systems was able to improve visibility, organize its workspace, reduce excess inventory, better utilize its workspace, and better fulfill customer orders. ...

Kaizen Events: Positive Impact on Internal Process: Via NIST: TG Fluid Systems USA: MEP Providing Hands-On Help to TG Fluid Systems ...

... "MMTC Lean specialists assisted TG Fluid in implementing the Toyota Production System values throughout the company. Lean Business Solutions allowed TG Fluid to align management personnel with the Lean ideology, and individual kaizen events and champion training allowed designated employees to see first hand the positive impact Lean methods have on internal processes. MMTC staff worked with TG Fluid material handlers to identify improvement targets. Results were immediate. " ...

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Tuesday, November 08, 2005

Kaizen in Public Service: New Mesa Manager ...

Justin Juozapavicius provides update on Mesa's city manager, Christopher J. Brady, who values the kaizen philosohpy of continuous improvement. ...

Kaizen in Public Service: New Mesa Manager : Via Arizona Republic: Mesa names new city manager

... "Brady, who is credited with landing a Toyota Manufacturing plant in San Antonio, and 2,000 jobs with it, said he adheres to the Japanese company's philosophy of Kaizen, which means continuous improvement. " ...

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Saturday, November 05, 2005

Kaizen: Toyota Ethos Constant Improvement ...

Doron Levin explores Toyota Motor Corporation's ethos of constant improvement: Kaizen, which is making business challenging for Detroit automakers. ...

Kaizen: Toyota Ethos Constant Improvement: Via Shanghai Daily: How to get more than 100 percent - ask Toyota

... "Breakthroughs in factory efficiency at Toyota are rarely big. Gain comes from countless little tweaks, encouraged by the automaker's ethos of constant improvement, known as kaizen in Japanese. " ...

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Wednesday, October 19, 2005

Customer Value Leadership: Kaizen Jidoka

Leadership is required to drive major transformation. John Baldoni explores the leadership competencies associated with the Toyota production system, based on driving customer value through kaizen and jidoka.

Customer Value Leadership: Kaizen Jidoka: Via CIO: Leading from Within ...

... "Toyota managers and employees operate on principles of just in time delivery, jidoka (quality) and kaizen (continuous improvement). All of these endeavors are focused to do one thing: Deliver value to the customer-value that the customer desires, wants and will pay for. " ...

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Sunday, October 02, 2005

Lean Six Sigma Methodology: Kaizen Competition

Lean Six Sigma Methodology: Kaizen Competition: Via Solectron: Solectron Drives Lean Six Sigma Manufacturing to its Suppliers: First Annual Award Judges Include Lean author, Jim Womack and Toyota Production System Expert Chichiro Nakao-San ...

Solectron drives operational efficiency through kaizen competition using its own flavor of the Lean Six Sigma Methodology ...

... "Solectron announced the Penang, Malaysia, facility as the winner of Solectron's first annual Global SPS Kaizen Competition. SPS is the company's industry-leading Lean Six Sigma methodology for continuous manufacturing improvement in quality and efficiency. Solectron employees have completed more than 5,000 Kaizens, a Japanese term that means continuous improvement, this year throughout its global operations. ... Entries for the contest were submitted from over 50 Solectron sites around the world. From those entries, 11 finalists from Europe, Asia and the Americas gathered in San Jose, Calif., to recognize the winner. Judges included Jim Womack, founder of the Lean Enterprise Institute and co-author of Lean Thinking and Chichiro Nakao-San, who spent over 30 years at Toyota Corporation refining its ground-breaking manufacturing methodology. ... Solectron's 2005 Supplier Day formally launched Solectron's Lean supplier program, which forms the foundation of Solectron's vision to deliver competitive supply chain solutions to its customers. The one-day event included breakout sessions on Lean 101, an introduction to the Solectron Production System; Solectron's Lean supply chain program; an overview of increasing customer value through design and engineering for Lean production; and Lean deployment from a supplier perspective. " ...


Solectron provides a full range of global manufacturing and supply-chain management services to the world's premier high-tech companies. Solectron's offerings include new-product design and introduction services, materials management, product manufacturing, and product warranty and end-of-life support. The company is based in Milpitas, Calif., and had sales from continuing operations of $11.64 billion in fiscal 2004.

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Saturday, February 19, 2005

Toyota TPS Kaizen Concepts ...

U.S.-Japan Investment Initiative ...

... "Toyota Motor Corporation has expanded local production in the U.S. since starting production in 1986 at New UnitedMotor Manufacturing (NUMMI) in California, a Toyota/General Motors joi