Toyota | AllAboutLean.com

The Toyota KPI Dashboard—Overview

Christoph Roser — Tue, 26 Sep 2023 11:00:25 +0000

Dashboards, in their many forms, are essential to track the performance of a production system. In this post I will talk more about the Toyota shop floor dashboard. A lot of the information is from Toyota in Japan, but the images are from Toyota UK. Keep in mind that the dashboards are not a rigid ... Read more

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On the Team Structure at Toyota

Christoph Roser — Tue, 04 Apr 2023 11:00:18 +0000

Toyota is (among other things) famous for its team structure on the front line. They have a quite low ratio of team members to supervisors, and I believe that is part of their success. Whereas many Western companies overstuff their hierarchy, at Toyota supervisors actually have the time to help their people and to also ... Read more

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Toyota’s New Type of Flexible Assembly Lines—Takaoka Line #2

Christoph Roser — Tue, 10 Jan 2023 11:00:29 +0000

Flexible assembly lines are well known at Toyota – except that there are two types of “flexible assembly lines.” The well-known one is making multiple different models on the same line. But Toyota has developed a new type of flexible assembly line, where the entire layout of the assembly line can be changed quickly and ... Read more

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Toyota’s Six Rules for Kanban

Christoph Roser — Tue, 25 Aug 2020 11:00:51 +0000

The kanban system is the most famous way to establish a pull system. As part of their guidelines for kanban, Toyota has established Six Rules for Kanban. They can be found, for example, in the 1973 Toyota Production System Handbook. This blog post describes these six rules, based on the Toyota handbook. While these rules ... Read more

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The Grand Tour of Japanese Automotive – Overview and Toyota

Christoph Roser — Tue, 27 Feb 2018 11:00:42 +0000

During Winter 2017–2018, I spent five months in Japan. As part of this visit, I was able to visit factories of all seven Japanese car makers as part of my Grand Tour of Japanese Automotive Plants. This was extremely insightful, and I learned a lot about the differences between the Japanese car makers. Let me ... Read more

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Continued Evolution of the Toyota Assembly Line

Christoph Roser — Tue, 20 Feb 2018 11:00:50 +0000

Toyota is one of the the most visionary car makers with respect to its manufacturing. They continuously and radically evolve and update their production system. Recently I learned about their new “flexible assembly line.” Now, you’ve probably heard about Toyota’s flexible assembly lines producing multiple products on the same line. That is old hat; they’ve ... Read more

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The Toyota Employee Evaluation System

Christoph Roser — Tue, 26 Dec 2017 11:00:18 +0000

Like most companies, Toyota conducts an annual evaluation of the performance of their employees. Recently I got a chance to look at these evaluation sheets and take notes. There are some surprising differences in the evaluation by Toyota in comparison to the evaluation by most other companies. Introduction Toyota evaluates its employees annually. When Toyota ... Read more

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Anatomy of the Toyota Kanban

Christoph Roser — Tue, 19 Dec 2017 11:00:19 +0000

While Toyota did not invent the pull system, they did invent kanban, the genius idea of using cards of paper (and later other forms of information) to create a pull system for mass-produced goods. I recently was able to take pictures of Toyota kanbans, and would like to show and explain them to you. Introduction ... Read more

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