1 sms text to his co-worker: "Hey remember that vertical screw set we had for the engine bay guys last week, bring it over for the TV crew I got something here". That's what Kaizen is all about. Communication and coordination. They didn't build it, they already been there.
ofc not, that if probably what they used normally. Funny thing is that you have to put a screw on your bit by a hand, everybody else is using screw dispencers + magnetic bits, so you don't even touch a screw with your hand.. not talking about holding 2nd screw in your hand while you have to screw in 1st one, imagine you drop it and then what? Dispence EXACTLY 2pcs again? Very pathetic improvement
This is serious stuff,I do these kind of things at my work where Kaizen is not even known, and people around me think I am some kind of wizard after a few days. This stuff is true power folks.
@@Yourmom-fl7nr I make tiny improvements in everything, and as weeks go by it builds like a vortex. For example I straighten picture frames as I go along, and that alone has people saying wow, the place looks cleaner, or putting small things away in their place. I could explain this much more, but the small things add up to serious change
I’m sure you think people think you are a wizard but I’m sure people don’t care 😂 unless the whole company culture is lean I think most people think this stuff is just random and a waste of time, unfortunately.
The Japanese are very wise people. There is no doubt about it and that is the reason why the brand value perspective Toyota is the most expensive among car brands
Japanese are over disciplined. It's failing their adaptability. They are pretty much unable to think outside the box at some point. Doesn't make the philosophy wrong tho.
dispenser that has screw in right position, drill bit is magnetized, now you can have the screw automatically placed and you can go in with the screw without even having to place it on
kaizen culture is very important. Because, we improve, So, company improve. I am working as a logistic assistans in Toyota motor manufacturing of Turkiye. Kaizen is very important for us.
I work at a toyota plant and the stretching thing is only for TV shows and tourists. Kaizen is real but often times people change good things into bad things and then back again
Here in France if someone came with that idea, first of all he would be hated by all others and then the factory would go on strike for 6 months and then 2 years to get the letter to the department head and then 1 year for him to read and during all this time it's time for new President and it will never happen.
It's just already been done, on another level. They probably have already perfected that position for the employee who most likely has better coordination and stamina than a drunk overweight british boomer who had a blackout when doing the morning stretch. lol
A few people in here commenting on robotics taking over from manual workers but the only thing that determines if a machine or a human gets the job is if the human can do the task quicker than a machine or, if a machine can’t cost effectively or possibly be made to do the task in place of them. That’s takt time.
Hopeful first month employee: I believe the screws could be easier to pick and screw. Toyota kaizen QA: Oi! We believe you arhhhhe incompetent! Oi! Kaizennnn reeee....jected! Try again oh next month you... Fired! Toyota kaizen OPS manager: *fist bump* we so kaizen bro *One month later* Employee arrives one morning to find a new auto-feeding screw driver set with a belt feed system to work non stop for 16 hour shifts. When he goes to complain to his Team leader this later one throws him a set of keys to a new supra parked outside and says. "Welcome to Toyota kid!" And they high five in the air as the frame stills and a nostalgic 80's montage song fades away in the background. *Don't youuuuuuu, fooooooget about meeeeee, Baby dont you dont yooooouuuuuu* (Yes I got the job)
Those exist for construction, you can get one at the following link: www.makitatools.com/products/details/XRF01Z They're not really for precision fastening though, they're built to point-and-shoot screws into lumber when doing production carpentry. Also, one of the tenants of lean production is to keep tooling flexible, and not commit too much capital toward producing a certain type of part in a certain way. This is to shorten lead times and make production as adaptable as possible. Perhaps an autofeed driver would not be so inflexible, but I don't think any such driver exists that's precise enough to drive machine screws into pre-tapped holes, and that can be fed with a variety of screw sizes. If that is the case (that no such driver exists) then Toyota would have to get someone to make it for them, which isn't the business they're in. That type of custom commissioning gets expensive. They may as well wait and see if someone else can make it work... a lot more buyers than just Toyota would be knocking on the door for one of those if someone could get the design right, and then Toyota could have it quite cheap.
Coming up with ways to do things better is one thing, being able to implement a working solution that fast is just as impressive! Be cool to know how much 1sec of savings equaled in cost per day/yr :)
there is sth called "risk analysis".if you don't see anything too risky about the area, why the hell would you bother people with burdens?further reading: fine kinney method.
With difficulty. First you optimize the process, then you automate it. If you just decide to use robots for everything, the engineer probably never did the lowly assembler job, so he's just giving it his best guess. Once it works, it is too risky and expensive to change it. All the foreman has to do is say "Give me the two and five year ROI on the cost of the change." and you'll just forget about it and go away.
Amazed how short sighted management and evil excessive greed, moved Boeing from actually following quality essentials, for goods where errors can result in near to certain death of people. RESPECTS TO TOYOTA AND JAPANESE COMPANIES THAT FOLLOWED, VEHICLES AT HOME ARE JAPANESE.
Am i the only one who will ask what is the compensation program for my monthly contribution to the company before shooting out my intellectual property? lol. Clever boys.
I can't believe they are using those dumb cross screw heads (Phillips). They are a pain to work with, slip and you can't control how much torque you need to apply. They should use star drive (torx) screws for this, much better, can't slip and you can tighten them as much as possible, untightening is also no problem. Does not cost any more money and prevents a lot of trouble.
@@sevinnosobretti1463 i guess you could make a case for that. But again, like I said, before the airbag incident, takata was a trusted supplier for many auto manufacturers. Toyota wasnt the only one affected.
@@sevinnosobretti1463 thats impossible to do because companies have merged and theres only so many suppliers that can produce parts at the quality and quantity needed for mass production
"Other industries adopted kaizen"? Not American companies. They only improve profits, not quality or production. (Which is why Toyota sells more vehicles).
![BLACK BAG - Official Trailer [HD] - Only in Theaters March 14](http://i.ytimg.com/vi/Du0Xp8WX_7I/mqdefault.jpg)
That quip about spare parts not being JIT was pretty sharp
I did not think they would build him that in one visit holy crap, hidden gem
1 sms text to his co-worker: "Hey remember that vertical screw set we had for the engine bay guys last week, bring it over for the TV crew I got something here". That's what Kaizen is all about. Communication and coordination. They didn't build it, they already been there.
ofc not, that if probably what they used normally. Funny thing is that you have to put a screw on your bit by a hand, everybody else is using screw dispencers + magnetic bits, so you don't even touch a screw with your hand.. not talking about holding 2nd screw in your hand while you have to screw in 1st one, imagine you drop it and then what? Dispence EXACTLY 2pcs again? Very pathetic improvement
Preconceived or not, making such a change to a workstation so easily and quickly is brilliant.
This is serious stuff,I do these kind of things at my work where Kaizen is not even known, and people around me think I am some kind of wizard after a few days. This stuff is true power folks.
Can you explain to me,please?
@@Yourmom-fl7nr I make tiny improvements in everything, and as weeks go by it builds like a vortex. For example I straighten picture frames as I go along, and that alone has people saying wow, the place looks cleaner, or putting small things away in their place. I could explain this much more, but the small things add up to serious change
I’m sure you think people think you are a wizard but I’m sure people don’t care 😂 unless the whole company culture is lean I think most people think this stuff is just random and a waste of time, unfortunately.
@@frikkied2638 your totally sure
Having a regularly scheduled quota of Kaizen is an amazing idea that can prevent stagnation and squeeze out ideas from all corners and perspectives.
no, it's stupid
@@michak8029 You must work at Ford.
Anyone else here because of their business work?
Why else lol. Its a production line philosophy mainly. Derived from perfectionism.
That’s my dad
Yup
yes
Yes
This video was so inspiring that I ask my husband to watch it with me, then I sent him to Home Depot so we can Kaizen our house
Thank you for the nice compliment in fact I’m his son and I’m soo proud of him
Legend has it your husband never returned home, but said branch of Home Depot is now the most efficient in the country....
Obrigado por compartilhar suas experiências, excelente trabalho.
what do you speak? sounder familiar to Spanish and if I understood correctly you said" thank you for sharing your experiences, excellent work."
Great clip and interesting look into the process of Toyota and how they apply Kaizen. Thank you for sharing!
The Japanese are very wise people. There is no doubt about it and that is the reason why the brand value perspective Toyota is the most expensive among car brands
Japanese are over disciplined. It's failing their adaptability. They are pretty much unable to think outside the box at some point. Doesn't make the philosophy wrong tho.
most expensive?are you forgeting companies like rolls royce bently morgan and even audi
@@collectorshaven722 He said brand value.
dispenser that has screw in right position, drill bit is magnetized, now you can have the screw automatically placed and you can go in with the screw without even having to place it on
kaizen culture is very important. Because, we improve, So, company improve. I am working as a logistic assistans in Toyota motor manufacturing of Turkiye. Kaizen is very important for us.
I work at a toyota plant and the stretching thing is only for TV shows and tourists. Kaizen is real but often times people change good things into bad things and then back again
Can add a slight magnetic property to the glove so that the screws will not spill.
Would have to be careful about workers with metal parts in their bodies though (due to previous surgery...)
Federal government is in desperate need of Kaizen
They're more than happy to run with fat, while the rest of us try to find ways to run leaner.
yeah, new kaizen being invented (from idea to tool) in a day, that's impressive!
Here in France if someone came with that idea, first of all he would be hated by all others and then the factory would go on strike for 6 months and then 2 years to get the letter to the department head and then 1 year for him to read and during all this time it's time for new President and it will never happen.
It's just already been done, on another level. They probably have already perfected that position for the employee who most likely has better coordination and stamina than a drunk overweight british boomer who had a blackout when doing the morning stretch. lol
@@TexasBoyDrew
I do not live or worked before with French people but I think you are overreacting
@@abdo206 trust me, I am not.
@@TexasBoyDrew
Ok then,
You clearly know something I don't know
Hang on brother
using employees skills and input to make incremental continuous improvement to the process
Yeah that doesn't happen in most businesses, managers with degrees in random sh*t get to make all the decisions and ignore the people who do the work.
A few people in here commenting on robotics taking over from manual workers but the only thing that determines if a machine or a human gets the job is if the human can do the task quicker than a machine or, if a machine can’t cost effectively or possibly be made to do the task in place of them. That’s takt time.
Hopeful first month employee:
I believe the screws could be easier to pick and screw.
Toyota kaizen QA: Oi! We believe you arhhhhe incompetent! Oi! Kaizennnn reeee....jected! Try again oh next month you... Fired!
Toyota kaizen OPS manager: *fist bump* we so kaizen bro
*One month later*
Employee arrives one morning to find a new auto-feeding screw driver set with a belt feed system to work non stop for 16 hour shifts. When he goes to complain to his Team leader this later one throws him a set of keys to a new supra parked outside and says. "Welcome to Toyota kid!" And they high five in the air as the frame stills and a nostalgic 80's montage song fades away in the background.
*Don't youuuuuuu, fooooooget about meeeeee, Baby dont you dont yooooouuuuuu*
(Yes I got the job)
I would have a self loading dispenser attached onto the Electric Screwdriver instead and have a bench with dispenser cartridges to reload a new one
Those exist for construction, you can get one at the following link: www.makitatools.com/products/details/XRF01Z
They're not really for precision fastening though, they're built to point-and-shoot screws into lumber when doing production carpentry. Also, one of the tenants of lean production is to keep tooling flexible, and not commit too much capital toward producing a certain type of part in a certain way. This is to shorten lead times and make production as adaptable as possible. Perhaps an autofeed driver would not be so inflexible, but I don't think any such driver exists that's precise enough to drive machine screws into pre-tapped holes, and that can be fed with a variety of screw sizes. If that is the case (that no such driver exists) then Toyota would have to get someone to make it for them, which isn't the business they're in. That type of custom commissioning gets expensive. They may as well wait and see if someone else can make it work... a lot more buyers than just Toyota would be knocking on the door for one of those if someone could get the design right, and then Toyota could have it quite cheap.
Shhh.. dont automate yourself out of a job lol
Coming up with ways to do things better is one thing, being able to implement a working solution that fast is just as impressive! Be cool to know how much 1sec of savings equaled in cost per day/yr :)
Great video, perfect example!
1:20_You are not supposed to have spare parts, that not JIT......hahahaahah......Who got this? hahaha
Big up westhatch
What program is this from?
How come no safety shoes n glasses??
there is sth called "risk analysis".if you don't see anything too risky about the area, why the hell would you bother people with burdens?further reading: fine kinney method.
What is this clip from? Thank you!
It's from a BBC programme called Building Cars Live.
where^***
The big question is, must we Kaizen using robots?
With difficulty. First you optimize the process, then you automate it. If you just decide to use robots for everything, the engineer probably never did the lowly assembler job, so he's just giving it his best guess. Once it works, it is too risky and expensive to change it. All the foreman has to do is say "Give me the two and five year ROI on the cost of the change." and you'll just forget about it and go away.
Is there a drawback for Kaizen?
Karōshi
I worked at this plant for a few years and I promise you its not at all like they'd have you believe.
Hanzhen harmonic drive gear , strain wave reducer, robot gear , over 30 years experience
Amazed how short sighted management and evil excessive greed, moved Boeing from actually following quality essentials, for goods where errors can result in near to certain death of people. RESPECTS TO TOYOTA AND JAPANESE COMPANIES THAT FOLLOWED, VEHICLES AT HOME ARE JAPANESE.
If only people in the Government used KAIZEN
Please , upload video how to reduce imm cycle time without any investment .
What are the time in which we can make change and reduce cycle time.
Sajjadinte andi
😂
Just keep some duct tape next to the steering wheel station in case you drop your screws. Done.
Am i the only one who will ask what is the compensation program for my monthly contribution to the company before shooting out my intellectual property? lol. Clever boys.
Everyone is supposed to share ip
Good thought, incremental pay raise?
Well this is my idea of engineering revision :)
kai cenat
No safety glasses 🤔
I can't believe they are using those dumb cross screw heads (Phillips). They are a pain to work with, slip and you can't control how much torque you need to apply. They should use star drive (torx) screws for this, much better, can't slip and you can tighten them as much as possible, untightening is also no problem. Does not cost any more money and prevents a lot of trouble.
Those are jis
I was going to make the same comment. Yeah... Phillips is goofy. Torques are great to work with and are superior
Hi
Why does it seem English speaking folk can't get into morning exercises or ritualistic shows of respect without giggling or feeling weird about it?
Because they need a coronavirus to realize the value of a Eastern custom like namaste or a traditional Japanese gesture.
Anyone here cause of dt
Still not understand how Toyota ended up involved in the Takata scandal despite its philosophy of constant improvement.
takata aren't part of toyota. They are a third party that supplied air bags to lots of other companies like honda, ford, etc.
@@ciello___8307 i still believed that Toyota neglected its supply chain
@@sevinnosobretti1463 i guess you could make a case for that. But again, like I said, before the airbag incident, takata was a trusted supplier for many auto manufacturers. Toyota wasnt the only one affected.
@@ciello___8307 lesson learned, don’t used the same suppliers of your competitors.
@@sevinnosobretti1463 thats impossible to do because companies have merged and theres only so many suppliers that can produce parts at the quality and quantity needed for mass production
I love that
India lacks nothing but kaizen
A half minute compulsory Kaizen clip before every video clip and boom!
"Other industries adopted kaizen"? Not American companies. They only improve profits, not quality or production. (Which is why Toyota sells more vehicles).
So then...what exactly is the point of having human beings at this factory then.....?
Kaizen-leading into schmalz...
Bruh
this thing aint nasty
I didnt understand
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Jerome Estates
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🎯 QUALITY, COMMITMENT AND CONTINUOUS IMPROVEMENT 🌺[[NANDAKUMAR DEVELOPMENT OFFICER LIC KALOOR ERNAKULAM]]
what
kaizen quota is stupid
take a basic task and add hundreds of failure points for the sake of thinking you're saving time and you got kaizen.
i dont think you have the right people leading
YJM YJM Aspects of Kaizen have been added to ISO standards used worldwide by manufacturing so I think it seems to work.
status quo much?