Earlier this month, Sarah K. Womack published a very interesting new book entitled Toyota's Improvement Thinking from the Inside: From Personal Transformation to Organizational Transformation, which describes how Toyota, through its coaches and leaders, develops its members’ capabilities through a series of continuous improvement (kaizen and problem-solving) activities. For many members of Toyota, this process results in a personal transformation that ultimately leads to organizational transformation.
When I spoke with Sarah this past week, I asked her: "What are the biggest misconceptions about Toyota’s continuous improvement methods and management system?” Here is her complete response:
The biggest misconception I personally had about Toyota’s continuous improvement methods and management system was a degree of personal development and deliberate challenge required to learn how to improve. It was a journey of mastery of improvement tools, business needs, and how to work with members of your team to accomplish daily objectives. For most members, that mastery was deeply personal and demanded humility and continuous reflection to transform our mindsets. And, while there was some talk about Toyota’s philosophy of respect for people, respect is a social construct and difficult to understand from outside of the group. Once I was inside, I saw how much emphasis there was on reducing team member burden towards the end of reducing waste and creating value for customers.
More generally speaking of the field, I find many misconceptions about how the entire system works together. Organizations tend to over-emphasize or de-emphasize the Toyota Production System (TPS) tools for improvement when a successful approach lands at a healthy balance. The TPS tools are good entry points for people development and continuous improvement. Value stream mapping, for example, is a tool to chart how material and information flows within a system, show waste, and tell a kaizen story (of waste reduction). Even if a system is not very complex, learning it through deep study then articulating that learning visually is a special skill set developed over time. You can feel confident in your skill set when you are able to use such a tool to tell the story of your improvement work.
Finally, I would highlight the misconception around standardization. Many organizations, within and outside of manufacturing, think it is too rigid to work successfully. However, Toyota and others have shown that by deeply studying processes and standardizing them, continuous improvements in safety, quality, and other performance outcomes are achievable.
What do you think about Sarah's experience? Has your company implemented a Lean initiative based on the Toyota Production System? Was is transformative?