Marksberry The Modern Theory of the Toyota Production System

A Systems Inquiry of the World’s Most Emulated and Profitable Management System
1. Auflage 2013
ISBN: 978-1-4665-8858-5
Verlag: Taylor & Francis
Format: EPUB
Kopierschutz: Adobe DRM (»Systemvoraussetzungen)

E-Book, Englisch, 451 Seiten

Numerous books have been written about Toyota's approach to workplace improvement; however, most describe Toyota's practices as case studies or stories. Designed to aid in the implementation of Lean manufacturing, The Modern Theory of the Toyota Production System: A Systems Inquiry of the World’s Most Emulated and Profitable Management System explains that your organization already has what it takes to succeed with TPS and what’s probably missing is balance.

Bridging the gap between implementation and theory, this text is the first of its kind to use systems theory to study how the pieces of the Toyota Production System (TPS) work together to achieve this much needed balance. Lean practitioners will learn how to use system theory to improve overall decision making when applying Lean or Toyota-like management systems.

Explaining that the glue that holds the pieces of TPS together is just as important as the pieces themselves, the book provides you with invaluable guidance in the implementation of Lean manufacturing from a management perspective. It outlines a blueprint to help you develop a clear understanding of how the pieces of TPS need to come together so you can achieve something greater than what’s possible with the individual pieces.

Zielgruppe

Vice Presidents, plant managers, team leaders, Lean practitioners, Lean consultants

Autoren/Hrsg.

Marksberry, Phillip

Fachgebiete

• Geisteswissenschaften Design Produktdesign, Industriedesign
• Wirtschaftswissenschaften Betriebswirtschaft Management Qualitätsmanagement, Qualitätssicherung (QS), Total Quality Management (TQM)
• Technische Wissenschaften Maschinenbau | Werkstoffkunde Produktionstechnik Fertigungstechnik

Inhaltsverzeichnis

Systems Theory and the Relation to TPS
Why Systems Theory for the Toyota Production System?
Why Systems Thinking Is Not Popular When Implementing TPS
Systems Theory Background
A Representation of Toyota’s TPS System Properties
Holism and Roles
Goal Seeking, Industrial Engineering, and Problem Solving
Regulation and Jishuken
Differentiation and Leadership
Hierarchy and Hoshin Kanri
Transformation, Change Management, and Kaizen
Entropy and Human Resources
Negative Entropy and Organizational Learning
Requisite of Variety and Production Leveling
Interrelationships and Supplier Development
Equifinality, Multifinality, and Maintenance
Summary
References

The Property of Holism in TPS
System Property: Holism
Holism and the Toyota Production System
The Role Concept
The Difference between Roles and Job Descriptions
Role Prescriptions
Role Theory and Analysis
Role Components and Features
The Emergent Properties of TPS: Teamwork
The Emergent Properties of TPS: Collaboration and Trust among Members
The Emergent Properties of TPS: Workplace Consistency
Summary
References
The Property of Goal Seeking in TPS, Part 1
System Property: Goal Seeking
Goal-Seeking Properties of the Toyota Production System
Background: TPS and the Industrial Engineering Connection
The Role of Industrial Engineering
Industrial Engineering Theory
Literature Review of Industrial Engineering Methods
The Scientific Management Era
Skill Sets of Industrial Engineers in the Era of Scientific Management
Skill Set: Scientific Method
Skill Set: Importance of Direct Observation
Skill Set: Work Sampling
Skill Set: Questioning Attitude
Skill Set: Standardization
Skill Set: Standards Engineer
Skill Set: Systems Thinking
Skill Set: The Process Flowchart
Skill Set: Work Distribution Charts
Skill Set: Time Study
Skill Set: Testing, Adaptive One Factor at a Time
Contemporary Industrial Engineering
Skill Sets of Contemporary Industrial Engineering
Skill Set: Systems Engineering and Optimization
Skill Set: Process Design and Reengineering
Skill Set: Experimental Design, Design of Experiments, Taguchi Methods
Skill Set: Six Sigma
Skill Set: Lean Sigma
Literature Review Summary
What Type of Industrial Engineering Identity Is TPS?
Differences between TPS, the Efficiency Expert, and Traditional Lean
Adapting Scientific Management to TPS and the Comparison to Contemporary IE
Standardization or Kaizen (Business Process Reengineering)?
Knowledge by Observation (Genchi Genbutsu) or by Inference (Data)?
Scientific Method or System Optimization?
Summary
References

The Property of Goal Seeking in TPS, Part 2
Problem Solving: The Identity of the Toyota Production System
Problem Solving versus Kaizen (Improvement)
Structured Problem Solving
Toyota’s Eight-Step Problem-Solving Methodology
Human Problem-Solving Background
Literature Review of Problem-Solving Methodologies
Limitations with Problem-Solving Methodology Research
Problem-Solving Theory and Core Thinking Skills
Criteria for Evaluating Effective Cognitive Processes
Applying Human Problem-Solving Theory to Toyota’s Eight-Step Process
Goal Clarity in A3 Thinking
Productive Thinking in A3 Thinking
Putting It All Together
Summary
References

The System Property of Regulation in TPS
System Property: Regulation
The System Property of Regulation and the Toyota Production System
Literature Review of Jishukens
Literature Review of Quality Circles
Using Quality Circles and Jishukens to Create a Shared Vision
The Weakening and Strengthening of TPS using Shared Visions
The Regulation Cycle of TPS
Jishuken and Quality Circle Implementation Concepts
Asking for Help and Promoting Waste Elimination
Starting Point for Workplace Improvement
The Team Structure of Jishukens and Quality Circles
Support Functions in QCs and Jishukens
Coach and Facilitate Problem Solving
Jishukens and QCs Must Advance Stability through Standardization
Model the Company’s Approach to Work
Summary
References

The System Property of Differentiation in TPS
System Property: Differentiation
Toyota Production System and System Differentiation
Literature Review of Leadership
The Distinction between Management and Leadership
Literature Review of Leadership Theory
Leadership Theory for TPS
The Why Function of TPS Leadership
The How Function of TPS Leadership
What If Leadership Is Not on Board with Defining, Coaching, or Implementing Lean?
The Where Function of TPS Leadership
The When Function of TPS Leadership
Summary
References

The System Property of Hierarchies in TPS
System Property: Hierarchy
The Hierarchical Property of the Toyota Production System
Decision Making in Hierarchies
Vertical Decision Making
Horizontal Decision Making
Interdependent Decision Making
Interdependent Performance
Monitoring and Progress
Routine Work and Nonroutine Work in Hoshin
Literature Review of Strategic Planning
Problems and Challenges in Strategic Planning
Strategic Planning Theories
A System of Hierarchies: The Hoshin Process
Planning Phase of Hoshin
Preparation Phase of Hoshin
Hoshin Implementation Phase
Hoshin Evaluation
End-of-Year Evaluation
A Theoretical Interpretation of Hoshin
Summary
References

The System Property of Transformation in TPS
System Property: Transformation
The Conversion Process in the Toyota Production System
Literature Review of Change Management
Conversion Process: Ingestor
Conversion Process: Motor
Conversion Process: Converter
Conversion Process: Producer
Conversion Process: Supporter
Conversion Process: Distributor
Conversion Process: Matter–Energy Storage
Summary
References
The System Property of Entropy in TPS
System Property: Entropy
Entropy in Organizations
Entropy in the Toyota Production System
Japanese Management Techniques in Human Resources
Japanese Management Practices and Toyota
Minimizing Entropy Using the Human Resource Function in TPS
Hygiene Theory and TPS: The Essential Needs of the Individual
Stable Employee Relations
Fair Appraisal and Treatment
Improve the Terms and Conditions of Employment
Workplace Communication
Motivation Theory and TPS: The Intrinsic Needs of the Individual
Decision Making
Teamwork
Workplace Competence
Summary
References

The System Property of Reversibility in TPS
System Property: Reversibility
Minimizing Entropy in the Management and Labor Relationship (Reversibility)
Literature Review: The Birth of the Toyota Production System as a Union
The Role of Trade Unions and the Human Resource Function in the United States
The Use of Lean in Human Resource Development
A Difficult Implementation of Lean in Union Environments in the United States
Union Problems and Lean Production in the Automotive Industry
A Successful Case of Lean Production in the Automotive Sector in a Union Environment
The Influence of Labor Unions in Japan on Lean Production
Internal Reversibility in TPS: A Union Perspective
Larger Employment Issues
External Reversibility in TPS: A Union Perspective
Summary
References

The System Property of Negative Entropy in TPS
System Property: Negative Entropy
Negative Entropy and the Toyota Production System
Exceptional Creativity, Mundane Creativity, and Lifelong Learning
Organizational Learning and Communication: Some Basic Similarities with TPS
Literature Review of Organizational Learning and Communication
Organizational Learning Theory
Connecting the Kaizen Mind
The Preferred Learning and Communication Style for the Kaizen Mind
Summary
References

The System Property of Requisite Variety in TPS
System Property: Requisite Variety
A Theoretical Response to Complexity and Variety
Toyota Production System and the Law of Requisite Variety
Literature Review: Production Leveling
The Technical and Social Structures of Production Leveling
Technical System: Prevention
Technical System: Reactive
Social System: Prevention
Social System: Reaction
Summary
References
The System Properties of Interrelationship and Interdependence in TPS
System Properties: Interrelationship and Interdependence
Interrelationship and Interdependence in the Toyota Production System
A Review of Toyota’s Supplier Development Practices
Building Positive and Interdependent Structures in TPS
Summary
References

The System Property of Equifinality in TPS
System Property: Equifinality and Multifinality
The System Property of Equifinality for a Management System
The System Property of Equifinality for Non-Value-Added Work Environments
Literature Review
The TPS Goal in Facilities Maintenance
The Tenants of Waste Elimination in Maintenance
Establishing Normal Work in Unknown and Nonroutine Work Environments
Fewer Higher-Skilled Employees
Seibi: Starting Point for Equipment and Maintenance Standards
Improving Equipment Availability Using Problem Solving
Summary
References

Summary
Systems Theory and the Modern Theory
Management System Properties Can Be Satisfied in Many Ways
Organizing the Properties of TPS for Implementation
Timing and Pace
How Do You Know When the Modern Theory of TPS Is Working?

Über Autor(innen)

Dr. Phillip Marksberry is the vice president of engineering and quality for American LaFrance, a custom manufacturer of emergency vehicles and modern fire engines. He received his BS in mechanical engineering at the University of Kentucky in 1997 and became board certified as a professional engineer in 2001. In 2000, he received his master’s degree in business management at Brescia University and in 2004 his PhD in mechanical engineering at the University of Kentucky. Dr. Marksberry has more than 20 years experience working in the automotive industry and holds several patents in metal cutting and product design. He has also held roles in production engineering, product design, industrial engineering, and operations. Prior to American LaFrance, he was a faculty member of the College of Engineering, with a joint appointment in the Department of Mechanical Engineering and Center for Manufacturing. Dr. Marksberry has published over 30 technical journal articles and has been a member of various technical societies.