On Wednesday we visited Toyota Motors in Toyota City.
Apparently Toyota City was originally named Koromo but renamed itself Toyota, essentially acknowledging that its future success was tied to the success of Toyota.
We had the opportunity to look around the Toyota Kaikan museum which actually had very good videos on the Toyota Production System and of course, fancy robots and concept vehicles:
Talking to Toyota managers
Before we went on the tour, we had the opportunity to talk to several Toyota managers.
Q: How are new plants developed?
A: They used to use a mother plant system. Supervisors and team leaders are trained for 6 months at the mother plant and people from the mother plant would be seconded for 1-3 years at the child plant. This system is no longer used due to recent rapid growth. Instead they've created a Global Production Centre.
Pay attention to the little things like ensuring that team leaders and team members eat together.
Teach people to see themselves as not just an assembly worker but also a quality worker. When Fujio Cho, the current Toyota chairman, was overseeing their expansion into the U.S. he personally thanked the first team member who pulled the andon cord at TMMK in Georgetown, Kentucky.
I think Gary Convis, former president of TMMK, said that Toyota has two requirements for team members:
- Show up
- Pull the cord
The Toyota Production System (TPS) is not a system; it's a religion. Please believe. TPS requires Total Participation and Total Agreement.
The line speed (i.e., takt time) of the plant is changed every month.
Machines are better than humans for some things. For example, tasks requiring high accuracy (e.g., painting) or are dangerous (e.g., welding).
Humans are better than machines for some things. For example, tasks requiring judgement (e.g., assembly).
Q: What are you looking for in people?
A: Openness to TPS, kaizen mind, system cost focus
The person who detects the problem should lead the problem-solving.
Plant Tour
The plant tour itself was run by a full-time tour guide I believe. There are a series of elevated walkways for you to peer down from. This was different than the Toyota Altona visit since that was on the floor itself and the guides are current or ex-employees.
A lot more robots in operation than Altona, and not just the big welding machines. Autonomous robots everywhere, pulling cars, providing parts, etc. It's very Star Wars.
The familiar music, which I'll describe as bad pre-polyphonic mobile ring tone music, was going off all the time as team members pull their andon cords.
When the cord is pulled the light flashes yellow and the chimes start. The team leader will come over to help. There is a section marker on the floor. If the problem is fixed or a work around is in place, then the cord is pulled again and the lights and music shut off. More complete problem solving may occur when the shift ends. If the section marker is reached before the situation is resolved, the light turns red and the line stops. Dependent lines start eating into their buffer stock. If the situation is not resolved when the buffer runs out, then they stop too. And so on and so forth.
740 000 improvement ideas by team members last year.
99.8% of improvement ideas are implemented. 500 - 200 000 yen rewards given depending on the significance of the idea.
There was a demonstration area to show fundamental skills training but better yet, there are videos of the plant champions that you can compete against. So I tried the rope exercise. Plant champion: 4 seconds. Me: 8 seconds. At this point, the plant manager had dropped by to see how we were doing. We asked him, "What is the standard for passing the exercise?" His answer: "4 seconds. If someone gets 5 or 6 seconds, we'll train them to the standard. Slower than that, we'll find them another position to do."
The best is the standard.
I missed it, but some other people in the group said they saw someone accidentally drop an engine. When the supervisor is called over (as the team member immediately signaled the problem), he doesn't look flustered at all but calmly works with the team member to check the engine, shows him what he did that caused him to drop the engine, and simply helps people work the situation.