The Modern Theory of the Toyota Production System : A Systems Inquiry of the World's Most Emulated and Profitable Management System

By (author) Marksberry, Phillip

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.

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[目次]

  • 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?

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この本の情報

書名 The Modern Theory of the Toyota Production System : A Systems Inquiry of the World's Most Emulated and Profitable Management System
著作者等 Marksberry, Phillip
書名別名 A Systems Inquiry of the World's Most Emulated and Profitable Management System
出版元 Taylor & Francis Inc
刊行年月 2012.12.17
ページ数 451p
ISBN 9781466556751
言語 英語
出版国 アメリカ合衆国
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