Toyota Problem Solving

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Toyota Problem Solving

• Its All About the Gap!

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Problem solving is Toyotas core way of doing
business
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Observations

• Toyotas official business model is a
  continuous problem solving model.
• Problem solving suffuses the organizations
  thinking, from plant presidents to office work to
  manufacturing floor team members.

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Observations

• Having no problems is a problem!
• True Toyota thinkers are pleased when they
  encounter a problem.
• No one has more trouble than one who says that
  he has no trouble. Taiichi Ohno, father of the
  Toyota Production System
• Being able to consistently meet work goals is a
  problem! (Well tell you why later.)

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The Essential
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A Toyota Problem
ClearWell definedMeasurableConnected to the
Ultimate GoalPart of a bigger systemVisual
ClearWell definedMeasurableVisual
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A Toyota Problem
ClearWell definedMeasurableVisual
And, therefore Actionable!
Will be
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What Makes Toyota Problem Solving Different

• Its just about identifying a problem and solving
  it.
• Its about
• being part of a bigger process
• that can be recycled continuously
• used on all levels
• and nested in deeper and deeper layers.

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Clarify The Problem
ClearWell definedMeasurableVisual
Will be
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Breakdown the Problem
ClearWell definedMeasurableVisual
ALL clear, well-defined, measurable, visualStudy
and confirm with Genchi Genbutsu (Go and See!)
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Set A Target
ClearWell definedMeasurableVisual
ClearWell definedMeasurableVisual
ClearWell definedMeasurableVisual
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Determine the Root Cause
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Countermeasure!
Critically evaluate effectiveness of various
countermeasures
Move to Action!!
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See Countermeasures Through
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See Countermeasures Through
NEVER Give Up!!!
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Monitor Both Results and Processes
Plan ? Do ? Check ? Action ? Plan ? Do ? Check ?
Action ? Plan ? Do ? Check ? Action ? Plan
ceaselesslyand with determination!
A good process, like a good garden, will yield
good results on an endless basis. Good results
without a good processis just luck.
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A Pause for A Couple of Questions
Question No. 1 For a standard that we are
supposed to be meeting right nowis it a good
thing to close the gap between whats actually
happening now (current situation) and whats
supposed to be happening (ideal situation)?
Question No. 2 If we are consistently and
reliably performing at an established standard,
is that a good thing?
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A Pause for A Couple of Questions
Question No. 1 For a standard that we are
supposed to be meeting right nowis it a good
thing to close the gap between whats actually
happening now (current situation) and whats
supposed to be happening (ideal situation)?
YES
Question No. 2 If we are consistently and
reliably performing at an established standard,
is that a good thing?
NO!!
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Two Kinds of Problems

• Event Problem
• When a defined standard of some type is not being
  achieved. The event is that failure to achieve
  the standard.
• Setting Problem
• When a standard is consistently being met and
  when business need dictates it, a new problem
  must be intentionally created by setting a new
  standard that is higher than the existing
  standard.

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The Common Factor

• In both Event-type problems and Setting-type
  problems the common thread is that the same type
  of thinking and processes are used to over come
  obstacles and achieve success in both cases.
• Thus, Toyota approaches all of its business
  needs by problem solving thinking.

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Standardize Successful Processes
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Human Development Problem
All Toyota General Maintenance Team Member have a
common defined multiskilled foundation.
Many Toyota General Maintenance Team Member do
not possess the complete set of defined
multiskills.
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Breakdown the Problem
Breakdown the Problem
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Set A Target
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Countermeasure!
Conduct College Partner Forum!
Critically evaluate effectiveness of various
countermeasures
Move to Action!!
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Q A