Stories from My Sensei : Two Decades of

In the tradition of Taoist philosophers and Zen masters, Steve Hoeft tells the stories he learned from his Toyota Production System (TPS) master teachers. Sometimes enigmatic, sometimes funny, but always powerful and enlightening, these stories of continuous improvement and lean implementation are organized around the Toyota House framework. After covering historical and foundational aspects of TPS, the stories go on to illustrate a wealth of essential topics encompassing the timeless, unchanging principles of Just-In-Time, Built-in-Quality, and Respect for People, and delves into specifics on many tools like kanban, Quick Changeover, and A3 Problem Solving.

Foreword	p. ix
Prologue	p. xiii
Acknowledgments	p. xvii
Summary of the Toyota House Model for Implementation	p. 1
The Toyoda Family	p. 4
Growth-The Growing Need for a Documented System of Model	p. 7
Not Tools	p. 9
Principles versus Tools	p. 9
Lean, TPS and Coming to America	p. 12
First View of the House	p. 13
Hey, My Favorite Tool Is Not in This House	p. 13
Sequence	p. 14
What Is a Sensei?	p. 15
Goals of TPS	p. 16
Changing Culture	p. 17
Foundation or Base Principles and Stories	p. 19
Standardized Work	p. 20
Preventive Maintenance	p. 21
Kaizen	p. 22
Robust Products and Processes	p. 22
Early Supplier Involvement	p. 22
My Most Interesting "Foundation" Stories	p. 26
Just-in-Time Pillar Principles and Stories	p. 63
JIT or the "Rights"	p. 64
Continuous Flow	p. 66
Pull	p. 67
Takt Time	p. 68
Cells	p. 68
Kanban	p. 69
Quick Changeover or SMED	p. 69
My Most Interesting JIT Stories	p. 70
People Pillar Principles and Stories	p. 87
The Power of Ideas	p. 88
A3 Problem Solving	p. 90
Employee Involvement and Empowerment	p. 90
My Most Interesting People Pillar Stories	p. 91
Built-In-Quality Pillar Principles and Stories	p. 111
Head Jidoka	p. 111
Never Pass Defects	p. 113
Stop the Line Authority	p. 114
Andon	p. 115
Problem Solving	p. 115
Error Proofing (Poka Yoke)	p. 116
My Most Interesting BIQ Stories	p. 116
Wrapping It All Up (The "Roof" or Results)	p. 131
What Is Success?	p. 132
Sweat and Blood	p. 132
My Most Interesting Roof Stories	p. 133
Closing Words	p. 145
Acronyms and Some Terms	p. 147
Recommended for Further Reading	p. 149
Index	p. 151
About the Author	p. 153
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Stories from My Sensei : Two Decades of Lessons Learned Implementing Toyota-Style Systems

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