The Toyota Way to Lean Leadership: Achieving and Sustaining Excellence through Leadership Development by Liker Jeffrey & Convis Gary L

Author:Liker, Jeffrey & Convis, Gary L. [Liker, Jeffrey]
Language: eng
Format: mobi
Publisher: McGraw-Hill Education
Published: 2011-11-07T05:00:00+00:00

Phase 1: Copying on a Pilot Basis

V.J. and his team first tried using the same “meat hook” system they had seen at Central Motors, but it didn’t work very well for them. The center of gravity of the different parts varied, so at times they would swing and hit one another, and some corners would bend. This created welding problems, since the bent corners could not mate properly. This happened at times at Central Motors, but it had a different welding system that pinched the body parts together during welding, and this compensated for some of the bends; TMMK’s system did not do this. In addition, workers had to walk among the parts to take them off the hooks, causing safety risk and wasted motion—certainly not ideal. Given these problems, the benefits of replicating the minomi system as it was employed at Central Motors weren’t enough to justify overhauling the parts-handling process. V.J. and his team realized that they couldn’t just copy what they had seen; they would need to innovate on the basic approach.

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