The Toyota Way Fieldbook: A Practical Guide for Implementing Toyota's 4Ps

  • 9h 20m
  • David Meier, Jeffrey K. Liker
  • McGraw-Hill
  • 2006

The Toyota Way Fieldbook is a companion to the international bestseller The Toyota Way. The Toyota Way Fieldbook builds on the philosophical aspects of Toyota's operating systems by detailing the concepts and providing practical examples for application that leaders need to bring Toyota's success-proven practices to life in any organization. The Toyota Way Fieldbook will help other companies learn from Toyota and develop systems that fit their unique cultures.

The book begins with a review of the principles of the Toyota Way through the 4Ps model-Philosophy, Processes, People and Partners, and Problem Solving. Readers looking to learn from Toyota's lean systems will be provided with the inside knowledge they need to:

  • Define the companies purpose and develop a long-term philosophy
  • Create value streams with connected flow, standardized work, and level production
  • Build a culture to stop and fix problems
  • Develop leaders who promote and support the system
  • Find and develop exceptional people and partners
  • Learn the meaning of true root cause problem solving
  • Lead the change process and transform the total enterprise

The depth of detail provided draws on the authors combined experience of coaching and supporting companies in lean transformation. Toyota experts at the Georgetown, Kentucky plant, formally trained David Meier in TPS. Combined with Jeff Liker's extensive study of Toyota and his insightful knowledge the authors have developed unique models and ideas to explain the true philosophies and principles of the Toyota Production System.

About the Authors

Dr. Jeffrey K. Liker is Professor of Industrial and Operations Engineering and Director of the Japan Technology Management Program at the University of Michigan. He is author of the international best-seller, The Toyota Way: 14 Management Principles from the World’s Greatest Manufacturer, McGraw Hill, 2004 (winner of the 2005 Shingo Prize and the Institute of Industrial Engineering 2005 Book of the Year Award). Previously he edited Becoming Lean: Experiences of U.S. Manufacturers (Productivity Press, 1997), winner of the 1998 Shingo prize (for excellence in manufacturing research). He has also won Shingo prizes for his research in 1995, 1996, and 1997. Other books by Dr. Liker include Engineered in Japan, (Oxford University Press, 1995); Concurrent Engineering Effectiveness: Integrating product development across organizations (Hanser-Gardner, 1997), and Remade in America: Transplanting and Transforming Japanese Manufacturing Methods (Oxford University Press, 1999). His most recent book, with James Morgan, is High Performance Product Development: How Toyota integrates people, process and technology to create a revolutionary lean product development system (Productivity Press). Dr. Liker is active as a keynote speaker, speaker for executive retreats, and lean consultant, independently and through a company he cofounded—Optiprise, Inc. Recent clients include DaimlerChrysler, Metalsa, Danfoss, Rio Tinto Mining, Caterpillar Asia Pacific, Benteler Automotive, Amcor, Federal Mogul, PPG Industries, Johnson Controls, Tenneco Automotive, Framatome Technologies, Northrop Grumman Ship Systems, Jacksonville Naval Air Depot, the U.S. Air Force, and Portsmouth Naval Ship Yard.

David Meier learned the Toyota Production System (TPS) as one of the first group leaders hired at Toyota’s Georgetown, Kentucky facility in the plastics molding department. He was trained and mentored in Japan and Kentucky over a ten-year period by TPS experts including full-time coaching by several Japanese coordinators. After leaving Toyota, David founded Lean Associates, Inc., a consulting firm that is dedicated to supporting companies that are pursuing implementation of the Toyota Production System.

David wrote two chapters for Lean Manufacturing: A Plant Floor Guide (Society of Manufacturing Engineers, 2001) and has been a trainer and speaker for over eight years. He has presented training workshops on Standardized Work, Value Stream Mapping, and Introduction to Lean Fundamentals for the Society of Manufacturing Engineers, and the Shingo Prize Conference. David has supported many companies in a variety of industries including automotive, aerospace, wood and plastic products, chemical processing, metal machining, fabricating, welding, and assembly operations in both manufacturing and non-manufacturing work areas. He specializes in developing TPS expertise within organizations so that they become capable of achieving lean transformation.

In this Book

  • The Toyota Way Fieldbook—A Practical Guide for Implementing Toyota’s 4Ps
  • Foreword
  • Background to the Fieldbook
  • Define Your Company Purpose and Begin to Live It
  • Starting the Journey of Waste Reduction
  • Create Initial Process Stability
  • Establish Standardized Processes and Procedures
  • Create Connected Process Flow
  • Leveling: Be More Like the Tortoise Than the Hare
  • Build a Culture That Stops to Fix Problems
  • Make Technology Fit with People and Lean Processes
  • Develop Leaders Who Live Your System from Top to Bottom
  • Develop Exceptional Team Associates
  • Develop Suppliers and Partners as Extensions of the Enterprise
  • Problem Solving the Toyota Way
  • Develop a Thorough Understanding of the Situation and Define the Problem
  • Complete a Thorough Root Cause Analysis
  • Consider Alternative Solutions While Building Consensus
  • Plan-Do-Check-Act
  • Telling the Story Using an A3 Report
  • Lean Implementation Strategies and Tactics
  • Leading the Change


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