[[blog/video-the-role-of-leadership-in-software-development-mary-poppendieck.md|Video_ The role of leadership in software development - Mary Poppendieck]] Want to Read Rate this book 1 of 5 stars2 of 5 stars3 of 5 stars4 of 5 stars5 of 5 stars Toyota Production System: Beyond large-scale production by Taiichi Ohno, Norman Bodek (Goodreads Author) (Foreword) 4.05 · https://www.goodreads.com/book/show/376237.Toyota_Production_System#https://www.goodreads.com/book/show/376237.Toyota_Production_System# https://www.goodreads.com/book/show/376237.Toyota_Production_System# Rating details · 1,315 ratings · 47 reviews In this classic text, Taiichi Ohno–inventor of the Toyota Production System and Lean manufacturing–shares the genius that sets him apart as one of the most disciplined and creative thinkers of our time. Combining his candid insights with a rigorous analysis of Toyota’s attempts at Lean production, Ohno’s book explains how Lean principles can improve any production endeavor. A historical and philosophical description of just-in-time and Lean manufacturing, this work is a must read for all students of human progress. On a more practical level, it continues to provide inspiration and instruction for those seeking to improve efficiency through the elimination of waste. (less) Get A Copy AmazonOnline Stores ▾Book Links ▾ Hardcover, 176 pages Published March 1st 1988 by Productivity Press (first published 1978) Original Title Toyota seisan hōshiki . ISBN 0915299143 (ISBN13: 9780915299140) . Edition Language English . Other Editions (13) All Editions | Add a New Edition | Combine …Less Detail edit details Edit My Activity Review of ISBN 9780915299140 Rating 1 of 5 stars2 of 5 stars3 of 5 stars4 of 5 stars5 of 5 stars Shelves to-read edit( 434th ) Format Hardcover edit Status June 30, 2019 – Shelved as: to-read June 30, 2019 – Shelved Review Add a review comment . Friend Reviews Recommend This Book None of your friends have reviewed this book yet. . 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Jun 23, 2011 Jan-Maat added it · review of another edition Shelves: business-management-pm, 20th-century, thinking, japan This is a book that sits for me in absolute contrast to Getting Things Done. In that book the employee is alone. The amount of work they are exposed to is more than they can cope with. Their manager is indifferent or incapable of assisting them, the company as a whole appears to have no interest in making sure that work is done with or without employees dying at their desks. The only solution is for the heroic individual to go forth and spend their own money buying the author’s book in order to be able to survive the American workplace. The experience is a common enough one for many copies of Getting Things Done to have been sold but rereading Ohno’s book on the Toyota management systems demonstrates how deeply weird and unbusiness-like the corporate life envisioned or even experienced by David Allen is. Ohno was given the task by the Toyoda family of catching up with American levels of productivity in the Toyota vehicle manufacturing business - itself an offshoot of the family’s loom manufacturing business. This was in the post-WWII period and some rough calculations showed that productivity per worker was nine times higher in the USA than in Japan. The work to achieve this goal of reaching US levels of productivity was slow, experimental and thoughtful. It required abandoning what had been conventional in automobile manufacturing as well as in bookkeeping and considerable faith. Perhaps oddly in his quest Ohno was inspired by the supermarket and by the autonomated looms (view spoiler) produced by the Toyoda family in the inter-war period which provided the finance for the development of their vehicle manufacturing business. Enroute to achieving that goal Ohno developed Kanban - a visual ordering system to force the factory to work like a supermarket - ie receiving an order for a car would then require the production of sufficient defect free parts to manufacture that car as opposed to the traditional method of manufacturing parts to maximum extent that the machinery would allow irrespective of whether the business could sell those parts or not. He also used the method of asking why five times to get to the root of problems, a Just in time manufacturing method, Production levelling, or as he puts it ensuring that the Mountains should be low and valleys should be shallow (p36) and a comprehensive effort to remove waste. Not waste purely in terms of physical rubbish, but in a broader sense of removing any activity, process or practise that does not add value to the manufacturing process. Reducing lot sizes and getting rid of stock inventory - or lowering the water level to expose the stones as it was called - was important here in identifying defective work and addressing the causes of this. Implicitly and explicitly there is a stress on having an approach that is appropriate for where you are. In Ohno’s analysis Ford or General Motors style mass production would not have been successful in Japan in the 1930s because the market was too small and too segmented. Mass production is successful when times are good, but a focus on reducing waste allows continued growth in profits even in low growth or recession situations - as this has the potential to free the business from needing to produce in bulk to achieve a low unit cost per item. Despite this Ohno is generous towards the Ford system and credits its innovations - even in what we might consider as an originally Japanese manufacturing concept such as reducing waste, to this effect Ohno quotes a section of Ford’s memoirs in which he reflects on the value of the scrap metal, and why his business processes were producing scrap in the first place. The first great thing about Ohno’s book is that it is short. I mean this in the positive sense. Many books are long, as though trying to justify the cover price, particularly it seems in business writing. An excess of words though is not quality. This book however is pithy. Concentrated. Flicking through it, a sentence catches my eye and the insights make me smile. Time was when Toyota was doing very well and one could brandish a copy of The Toyota Way as through it offered an answer to any problem. In Ohno however there is something more, a sense of the attitude or a state of mind that one could cultivate in yourself based on a respect for the work of others. This is where the contrast with the world revealed in Getting Things Done comes in. This is a world in which the management works towards the effective functioning of the business as a whole. Not one in which people are left to flounder. The motivation may be more practical than humanitarian, but there is a clear assumption of responsibility. Interesting and revealing is the role of nationalism, perhaps even of racism in motivating the Toyoda family and Ohno. Success in manufacturing was felt to demonstrate Japanese ingenuity and creativity and therefore proof that they are not inferior to Europeans (pp88-92). This is not the kind of thing one would find in an economics textbook but are the kinds of feelings that do or can motivate people. The odd hagiography that Ohno cites of Toyoda the loom designer reminds me that I heard that many founders of major Japanese companies are regarded as being Kami. The world around us looks modern, but only because we don’t see the tradition beneath the surface. Some of the approaches discussed by Ohno including reducing batch sizes and reducing inventory are shown in practise in the novel The Goal, which might be a more appetising way to consuming some of these ideas than Ohno’s book. The Toyota Way puts Ohno’s work in a broader context and with more attention paid to actual production rather than the principles discussed here. (less) flag 28 likes · Like · 8 comments · see review Mar 01, 2016 James rated it really liked it Shelves: non-fiction I read this in the late 80’s and reread it recently, it’s the philosophy and history of the Toyota Production System, later called by other names including Just In Time. Locally this system was used to turn the Fremont NUMMI plant from GM’s worst car plant to its best by only changing out management. GM has no other plant in North America that was able to convert to this system and used their bankruptcy as an excuse to close the plant that was embarrassing their management. It’s key aims are to eliminate wasted materials and idle workers. While Ohno says this is a better management method, when carried to its logical conclusion, you get things like the Toyota slaves and hideous pressures on subcontractors. I don’t plan on singing the Toyota company anthem anytime soon. (less) flag 3 likes · Like · comment · see review Jun 27, 2017 Anton Iokov rated it really liked it Shelves: physical-books 5 stars for ideas and 3 for the writing. I wish Belarusian factories started implementing just-in-time manufacturing at least in the 21st century. However, there’s another book on the manufacturing flow optimization that I would rather recommend: The Goal: A Process of Ongoing Improvement. The content is similar, but Goldratt is more easy to read. flag 2 likes · Like · comment · see review Jan 25, 2015 Mark rated it really liked it · review of another edition Good book, yet I believe many will be disappointed. First, some will expect a relatively complete framework. It doesn’t have that. There is a lot of history that many may not expect, yet I greatly appreciated. I especially enjoyed the historical context, the relationship between Japan and the U.S., and the sharing of ideas across the countries (much of which came back this way and formed Agile and Scrum concepts which are heavily used in the Software world… and are a huge help). Some will be disappointed in some of the wording possibly affected by translation and at times possibly because of the authors propensity to word some concepts with strong feeling. I’ve seen some reviews (before I bought and read) that said the author worded things succinctly, thus the book was short. I felt that the wording efficiency depended on the area, and in some areas that the author felt strongly, it could be more verbose. It was less so when he was simply describing things. At times I had to work hard to decipher the meaning because I felt some details were left out. Upon a 2nd (or 3rd) reading I got it, but it was work sometimes to get it. The great part to me is the context and impact of the core pillars of the Toyota Production System. The author made those clear and conveyed well how much they helped. I gathered many valuable tips that I can implement (e.g. the value of visibility of problems, progress, systems, the longer-term vision of stopping the line and fixing on the spot, the concept of refusing to allow patches to a system that encourage a creeping (and consuming) mediocrity. I’m glad I read this and may read it again after a while, and after applying applicable parts. (less) flag 1 like · Like · comment · see review Jul 09, 2013 Pavleras rated it liked it although I’m not interested in manufacturing this book has been very interesting to understand the reasons and background behind TPS. this book doesn’t give any comment on how to apply TPS. It’s also interesting the comparison between Ford and Toyota approach. flag 1 like · Like · comment · see review Oct 01, 2012 Bob Wallner rated it really liked it Shelves: re-read, lean This is a reread of Ohno’s classic work in preparation for my SME Lean Silver Certification. This is not my favorite book on lean or Toyota but, is a classic and clearly lays out what Ohno-san thought the Toyota Production System was all about. flag 1 like · Like · comment · see review Jan 23, 2018 Matt rated it really liked it This is a great book not just about manufacturing but offers some good philosophy about improving any business (plus an interesting history of Toyota). The fundamental philosophy: eliminate waste. What’s interesting is how he defines waste. For example, time spent moving parts to a storage area and then back to the production line is waste. The warehouse holding inventory is waste. Anything that doesn’t lead directly to building the final product is waste. With this foundation, they completely r …more flag Like · comment · see review Oct 15, 2018 Arpita K rated it really liked it Shelves: half-read, technical, have This review has been hidden because it contains spoilers. To view it, click here. flag Like · comment · see review Mar 21, 2018 Nikolay rated it liked it Shelves: productivity, management, lean, business Overview of the Toyota production and management system and history from one of it’s founder. It mainly describes three basic principles: Just-In-Time, Kanban and Autonomation. Book is not very well written, and sometimes author jumps from topic to topic rapidly. But it is quite short and still very valuable reading for engineers and managers of production projects. flag Like · comment · see review Apr 06, 2019 Alex rated it really liked it This review may seem inconsistent but my takeaways are people do oversimplify Kanban. deep understanding and proper use of simple tools (like Kanban) are the keys in making production profitable start with need ask “Why?” 5 times reverse common thinking (sense) pursue just-in-time (be as lean as possible) be creative flag Like · comment · see review May 12, 2018 Krystof rated it really liked it Shelves: non-fiction Handy introduction to the principles of lean manufacturing in Toyota, providing foundations for numerous non-manufacturing applications - from scrum and agile project management to lean startups. Short, concise, written in a simple and matter-of-fact style. “Progress cannot be generated when we are satisfied with existing solutions.” flag Like · comment · see review Apr 07, 2019 Michael Ross rated it really liked it Great read that explains the origins of the TPS. No formulas. No big words. Just theory and results of the theory. flag Like · comment · see review May 28, 2017 Vincent M. rated it it was amazing Fundamental to learning lean, practicing lean and coaching lean. flag Like · comment · see review Sep 25, 2017 Mike Thelen rated it it was amazing From the mastermind behind the system. What else would one need to know? flag Like · comment · see review Feb 05, 2018 Sean Helvey rated it liked it Nice reminder that Deming didn’t come up with this stuff, and that goes all the way back to Ford. Nuggets of wisdom, not super cohesive, but fun to skim through! flag Like · comment · see review Mar 06, 2017 Justin Aquino rated it it was amazing We’re entering a low growth cycle and this book’s key principles are very important now. This is a helpful book but this is just one of many many books, and implementation attempts one needs to do to really understand its key concepts and to communicate it in a company that has no clue about it nor inclination to learn or get around to reading much less studying the many other books about the matter. Read this book and many others that help form your understanding and feel terribly alone and powerless to implement it, as implementation means making mistakes, painfully slow gains, and while being surrounded by charlatans that sell panacea and those with their best interests against the implementer. (less) flag Like · comment · see review Apr 23, 2011 Mike Knox rated it really liked it Shelves: non-fiction, business-leadership In this book Taiichi Ohno, one of Toyota’s famous innovators, discusses the Toyota Production System (TPS) that he developed. So much of what he says is simple. He surely wasn’t the first business leader to focus on reducing the time line “from the moment the customer gives us an order to the point when we collect the cash” (ix). And the TPS doesn’t seem very profound when he states that its’ “most important objective…has been to increase production efficiency by consistently and thoroughly eliminating waste” (xii). And yet the underlying concept of a pull system rather than a push system, and the mechanisms for implementation (just-in-time, autonomation, and kanban) are anything but simple. Toyota’s entrance into and dominance within the automobile industry is an amazing story of innovation and challenging existing assumptions. I also appreciated Taiichi Ohno’s respect for humanity. While Toyota tries to eliminate workers from its payroll in order to achieve profits, they seek to respect the workers they do employ by making them responsible for their quality and by organizing processes so that no one is just watching a machine. Though this is the Toyota production system, the applicability of the concept for any type of business is emphasized throughout the book (e.g. p.9). (less) flag Like · comment · see review Apr 04, 2013 Chris rated it liked it Shelves: business The “Toyota Production Method” is Taiichi Ohno’s 1978 description of the Toyota production system, it’s motivations and it’s philosophical underpinnings. Father of the lean production methods of modern manufacturing and, more recently, agile programming methodologies it is a boom worth reading for a historical perspective and some insights lost in later development. What’s more, written at a time of low growth in Japan, it may hold even greater relevance today than it did 5 years ago. A solid 4 stars. The remainder of this review is my bulleted synopsis of some key ideas for my own records: - Key insight: Capacity = useful work + waste, therefore reducing waste means greater profits - Autonomisation of employees, intelligent use of automation and just in time (limit: production runs of 1) minimise waste - Achieving this requires time, deliberate learning and close coordination with partners and employees, plus clear drive from organisational leadership - Deliberate attention to mistakes and their correction using “5 Why’s” along with deliberate attention to workflow and standardisation are also key - in comparison, while mass production is superficially more efficient it often sacrifices efficiency for volume and speed (less) flag Like · see review Jan 12, 2008 Jeff Gramm rated it liked it Taiichi Ohno tells us how he revamped Toyota’s (and thus everyone else’s) auto manufacturing processes. This multi-decade project required altering the company’s (and its suppliers’) fundamental approach to production through a succession of process changes that would seem impossible for any large, labor-intensive companies to accept. While the book gets too technical in parts, it is filled with many insights and lessons. I’ve never read about manufacturing before, and it just amazes me how teeny tiny process changes can create conditions that motivate workers to find clever ways to reduce inefficiency. Ohno’s patience is also something to wonder at: He had a clear vision for changing auto manufacturing, but he knew because of the nature of workforces and large organizations, it would take many years to make it a reality. Yet he pulled it off. . .sorta crazy. It’s also funny to compare the Henry Ford “let’s build as many fucking cars as we can and our scale will make up for all of our inefficency” approach to Ohno’s low-inventory, low-defect and no-waste achievement. (less) flag Like · 1 comment · see review May 29, 2017 Dave rated it it was amazing The book packed a large number of concepts that changed the shape of manufacturing worldwide in a very small space. It is extraordinary that so much was gained from such a simple source. One could use this book as a useful pocket guide. Of course, a newer book like The Toyota Way by Jeffrey Liker probably handles the topic more thoroughly, but it is nice to read a book from one of the inventors so that you can see the thinking and perspective from the ground up. This is the type of book that I will read over and over. I enjoyed reading the straightforward style and could see how and why Taiichi Ohno created the Lean system. It enables you to get grounded in the grass roots of the Lean Manufacturing movement. It gives you an important perspective and enables you to understand its original intent. You will then create the skills to assess the different evolutionary steps of the process and know more pointedly what each step was created for. It’s always good to go “old school”. For a full review, please go to my website at https://davemolinari.com/2017/05/28/b… (less) flag Like · comment · see review Aug 05, 2007 Hardcore rated it liked it For anyone interested in the Toyota Production System (TPS, often called “Lean Manufacturing,” or simply “Lean” in the US), this is a must-read. This book is not like Jeffery Liker’s “The Toyota Way.” This is a personal account given by one the production system’s architects, Taiichi Ohno. While books such as Liker’s “Toyota Way” may give insight from a managerial perspective, Ohno presents his story (and it does read much like a narrative) in a historical frame. Through reading this, one sees t …more flag Like · comment · see review Oct 31, 2014 Evan Leybourn rated it really liked it Understanding TPS, and the subsequent evolution into lean manufacturing, is critical to any business leader. This work is seminal in the field, and should be considered compulsory reading. I’d also recommend that anyone interested in the history of TPS also read “The Machine that Changed the World”. My only criticism of this book, and the only reason it doesn’t get 5 stars, is that it doesn’t provide a lot of depth, nor much in the way of practical advice, on lean manufacturing. Although, in the …more flag Like · comment · see review Sep 28, 2014 Kai Weber rated it did not like it · review of another edition Shelves: economy There’s nothing wrong with the Toyota production system (TPS), I think. But if this book were the “standard work on the TPS”, as the advertorial blurb proclaims, then one couldn’t get very far with this system. Heavily redundant, randomly jumping, overly colloquial. Mr. Ohno has merits for his role in developing the TPS, and it is probably OK to listen to this old man talk about his life’s work for a while, but he’s definitely not a gifted writer. Pity to see an interesting topic to be treated s …more flag Like · comment · see review Jan 06, 2013 Lamec Mariita rated it it was amazing This is a very enlightening work by the inventor of lean manufacturing, Taiichi Ohno. If you are interested in getting started in the Lean methodologies then you should read this book. Taiichi Ohno makes us understand why Toyota Production System is what it is. He shares with us his experience introducing several concepts to be more productive. It’s a good read. flag Like · comment · see review Jun 26, 2016 Pawan Kumar rated it it was amazing Right from the horse’s mouth! Written in a crisp, clear and concise manner, this book unveils the making of TPS. I found the concepts extremely relevant and common sense approach to the context set in the beginning of the book. While the management case studies do bring some insights, this book is a step ahead in the right direction. A must read only if one is an operation enthusiast. flag Like · comment · see review Jan 21, 2012 T.S. rated it it was ok I read this for work and found it interesting enough. It’s an easy read, though some sections are more technical and others too mundane. I work at a nonprofit, but the principles in the book can be applied, as well as any other workplace. flag Like · comment · see review Jul 17, 2014 John Corcoran rated it really liked it The translation seems ropy and the book as a whole lacks cohesion, but there are enough gems in here to make it well worth a read. Fascinating to read about the origins of many of the principles we use in the team I develop software in. flag Like · 1 comment · see review Aug 25, 2010 Brian Rashap rated it it was amazing Anyone that is seeking more to learn about Lean or the Toyota Production System should check out this book. The founder of TPS talked about his own learning journey and I believe gives great insights into anyone that wants to live Lean, rather than just copy the motions. flag Like · comment · see review Mar 16, 2013 Dan added it Interested in lean production or lean development? Read this first. flag Like · comment · see review Feb 20, 2011 Gareth Townsend rated it really liked it I’m glad I had a crash course in Lean Software development before reading this book. It made understanding the principles of the Toyota Production System much easier. flag Like · comment · see review « previous 1 2 next » . new topic Discuss This Book topics started by posts views last activity Means of Production Ugly Christmas Sweater Myfrogtee 1 (1 new) 1 Nov 27, 2017 07:17PM More topics… .