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The Toyota Way Fieldbook (Paperback)

~ Jeffrey Liker (Author), David Meier (Author) "Toyota's success as a company has been well documented..." (more)
Key Phrases: standardized work sheet, process owner, connected process flow, Toyota Production System, Six Sigma, Case Example (more...)
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Editorial Reviews

Product Description

The Toyota Way Fieldbook is a companion to the international bestseller The Toyota Way. The Toyota Way Fieldbook builds on the philosophical aspects of Toyota’s operating systems by detailing the concepts and providing practical examples for application that leaders need to bring Toyota’s success-proven practices to life in any organization. The Toyota Way Fieldbook will help other companies learn from Toyota and develop systems that fit their unique cultures.

The book begins with a review of the principles of the Toyota Way through the 4Ps model—Philosophy, Processes, People and Partners, and Problem Solving. Readers looking to learn from Toyota’s lean systems will be provided with the inside knowledge they need to: • Define the companies purpose and develop a long-term philosophy • Create value streams with connected flow, standardized work, and level production • Build a culture to stop and fix problems • Develop leaders who promote and support the system • Find and develop exceptional people and partners • Learn the meaning of true root cause problem solving • Lead the change process and transform the total enterprise

The depth of detail provided draws on the authors combined experience of coaching and supporting companies in lean transformation. Toyota experts at the Georgetown, Kentucky plant, formally trained David Meier in TPS. Combined with Jeff Liker’s extensive study of Toyota and his insightful knowledge the authors have developed unique models and ideas to explain the true philosophies and principles of the Toyota Production System.

From the Back Cover

Your hands-on guide to the secrets of Toyota's success!

Jeffrey Liker first revealed the management principles Toyota's worldwide reputation for quality and reliability in the international bestseller The Toyota Way.

Now, he and Toyota veteran David Meier take those lessons a step further with The Toyota Way Fieldbook. You'll receive the diagnostic tools, worksheets, and exercises--many adapted from Toyota originals--so you can craft the most effective approach for your organization.

Learn how to develop a long-term philosophy of cost reduction, build a culture that stops to fix problems quickly, develop leaders that live your system, and transform your company into a true lean learning organization that continuously improves, meets the needs of its customers, and positions itself for long-term success.

Most importantly, you'll understand the thinking behind lean tools and approaches so you can implement Toyota's 4P Model for success in your organization:

Philosophy--The company is a vehicle for adding value to customers, society, the community, and its associates.

Process--When leaders follow the right process they get the right results, including long-term cost-reduction and quality improvement.

People and Partners--Add value to an organization by challenging its people and partners to grow and become more skilled and confident.

Problem solving--Continuously solve root problems to drive organizational learning.

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Product Details

  • Paperback: 476 pages
  • Publisher: McGraw-Hill; 1 edition (September 28, 2005)
  • Language: English
  • ISBN-10: 0071448934
  • ISBN-13: 978-0071448932
  • Product Dimensions: 9.1 x 7.3 x 0.7 inches
  • Shipping Weight: 1.6 pounds (View shipping rates and policies)
  • Average Customer Review: 4.7 out of 5 stars  See all reviews (30 customer reviews)
  • Amazon.com Sales Rank: #8,033 in Books (See Bestsellers in Books)

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    #2 in  Books > Professional & Technical > Engineering > Industrial, Manufacturing & Operational Systems > Productivity
    #4 in  Books > Nonfiction > Automotive > Industry
    #5 in  Books > Business & Investing > Management & Leadership > Industrial

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More About the Authors

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Jeffrey K. Liker
Jeffrey K. Liker
David Meier
David Meier

Front Cover | Table of Contents | First Pages | Index | Back Cover | Surprise Me!
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Inside This Book (learn more)
First Sentence:
Toyota's success as a company has been well documented. Read the first page
Key Phrases - Statistically Improbable Phrases (SIPs): (learn more)
standardized work sheet, process owner, connected process flow, connected value stream, lean coach, cycle balance chart, lean learning enterprise, fixed position stop, lean sensei, value stream approach, cycle time losses, leveled schedule, takt rate, point kaizen, genchi genbutsu, improvement spiral, takt time, lean value streams, sequenced flow, lean metrics, lean tools, kaizen workshops, lean activities, job instruction training, current state map
Key Phrases - Capitalized Phrases (CAPs): (learn more)
Toyota Production System, Six Sigma, Case Example, North America, Leading the Change, Create Connected Process Flow, Culture That Stops, Fix Problems, United States, Develop Exceptional Team Associates, Create Initial Process Stability, Quality Circles, Develop Leaders Who Live Your System, Starting the Journey of Waste Reduction, Case Study, Make Technology Fit, Telling the Story Using, Fax Machine, Value Stream Family, Thorough Understanding, Big Three, Load Fixture, Tale of Two Pistons, Toyota Technical Center, Instruction Training
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The Toyota Way Fieldbook
78% buy the item featured on this page:
The Toyota Way Fieldbook 4.7 out of 5 stars (30)
$19.77
The Toyota Way
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The Toyota Way 4.4 out of 5 stars (101)
$18.45
Toyota Culture: The Heart and Soul of the Toyota Way
2% buy
Toyota Culture: The Heart and Soul of the Toyota Way 4.6 out of 5 stars (14)
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Creating a Lean Culture: Tools to Sustain Lean Conversions
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Customer Reviews

30 Reviews
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Average Customer Review
4.7 out of 5 stars (30 customer reviews)
 
 
 
 
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26 of 26 people found the following review helpful:
5.0 out of 5 stars The best book for lean implementers, December 2, 2005
By Michael Balle (Paris, FRANCE) - See all my reviews
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This temendous book is the best book I have read on the specifics of TPS so far, and the one closest to it's elusive spirit - it's an absolute must read for any lean implementer. Far beyond the description of tools, it's a brilliant attempt at giving a feel for what TPS is truly about. For instance, there's a lovely story of one of the authors looking at a westerm traditional automotive assembly chain. At some point, he spots a problem with a carpet in the cars being assembled. Instinctively, he looks for the andon cord, before reminding himself that, of course, there would be one. Then he points out the defect to the supervisor, who answers, that, yeah, he's right - they'll probably spot it at rework and deal with it. Should they talk to someone upstream? Not necessary, the previous process is probably aware of the problem and trying to do something about it. The author then describes his moment of total anguish at seeing a defect go through the process and not being able to do anything about it.

This, I believe is a reflection of the true TPS spirit. I know a plant manager who used to work with Toyota before chosing to come back home and take a local non-Toyota plant. The first thing he did was set up an andon board. At first, he was puzzled to see the lights never went off. Then he realized there was nothing, but absolutely nothing in the current social system of the plant that would make the operators trigger an andon signal, or the management react to it. To implement TPS, everything had to be constructed from scratch.

The Toyota Way Fieldbook is far more than a companion to The Toyota Way, which is a great management book about Toyota. The Fieldbook goes explicitly into some of the least described aspects of TPS: the development of people thorugh constant problem-solving. The Fieldbook describes both techniques to follow people development, and problem-solving processes which are, in my mind, at the heart of the TPS. I can't recommend this book enough to all readers out there who struggle in trying to implement lean without access to a sensei. This won't replace the sensei, but it's the closest thing to it.
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6 of 6 people found the following review helpful:
5.0 out of 5 stars One more Jewel, October 14, 2005
Hats off to Dr Liker in bringing one more precious book to us.

Everyone can read this book with ease and understand Toyota principles through case studies.

Among many things I liked

1) Flow diagrams, TIPS, TRAPS, case studies and most importantly the visuals
2) More clarity on leveling paradox with examples
3) Toyota technology adoption strategies
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6 of 6 people found the following review helpful:
5.0 out of 5 stars Practical and useful "how to" companion to the Toytota Way, July 16, 2007
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Book description: what's the key message?

While Jeffrey Liker's book The Toyota Way was an examination of the 14 Principles of the Toyota Way, it was not an explicit "how to" guide at a tactical level. This follow up book is intended as the more practical guide to Becoming Lean (to borrow the title of an earlier book written by Liker). The Fieldbook is organized in the framework of Toyota's 4 P's:

* Philosophy
* Process
* People and Partners
* Problem Solving

The book starts first with "philosophy," not lean tools. It develops an important relationship between the two. The book, in its entirety, emphasizes that copying Toyota tools, regardless of how thoroughly, is not enough to become lean. Early chapters talk about defining your company's purpose and philosophy, providing many examples of Toyota's purpose and unique view of their place in society and the world. From there, the Fieldbook guides you through a reasonable progression of lean topics and methods to work with in your own company. While there is no simple linear progression through a lean transformation, the authors address the challenge well in structuring the flow of the book. Typical "early" stages of lean learning and implementation are covered first, including learning how to identify waste, establishing process stability, and developing flow. The book spends more time on organizational culture and management methods, as opposed to tools. The book remains practical and actionable, rather than theoretical.

A strong central portion of the book focuses on developing leaders, how to lead in a lean environment, and how to develop "exceptional" employees. One particular highlight are the detailed examples, including a breakdown of the roles of Group Leaders, Team Leaders, and Team Members in a lean setting, not covered in most lean books.

The book recognizes that companies are not Toyota as a starting point. Rather, they are trying to become a Toyota-like lean organization. There is a chapter on respecting suppliers and managing them as Toyota does. The last sections of the book cover Toyota problem solving and implementation strategies, including a discussion of the pros and cons of different common lean transformation or implementation approaches, including kaizen events and the development of a "Company Production System."

How does it contribute to the lean knowledge base?

This book is a unique compilation of Toyota Production System methods, concepts, and philosophies. There are many adaptable examples of Toyota tools and methods, including Standard Work Combination tables, Cross Training matrices, 5 Why's problem solving analysis, and A3 reports. There are many new case study examples in the book that will be helpful, even to an experienced lean practitioner.

The book is also unique in that it is co-authored by a former Toyota team leader, an American, as opposed to reading an older book by Toyota executive Taiichi Ohno or consultant Shigeo Shingo.

What are the highlights? What works?

The book is very readable and easy to understand. Its layout and format borrows many of the good practices of the "For Dummies" series. You might consider this to be a "Toyota Production System For Dummies" book. There are many callouts with icons indicating "Tips" and "Traps" to look out for in your own lean implementation, to help avoid common lean implementation mistakes or failure modes.

This is very helpful, as the authors realize that it can be difficult work implementing lean. They never talk down to you or make you feel bad that you might struggle with the Toyota Way in your own environment, because you are not Toyota.

Furthermore, co-author David Meier was a group leader at Toyota. Many perspectives on Toyota come from the process or industrial engineering perspective, but the perspective of front-line supervisor is of significant value and often overlooked.

What are the weaknesses? What's missing?

While this is clearly a field book in its application focus, it is less clear how it is connected to companion book, The Toyota Way. The 14 principles of that book are mentioned briefly but are not integrated into this book. The Fieldbook has value as a standalone volume, but those looking for a specific companion to The Toyota Way will be disappointed.

You might be surprised to not find much information about Kanban, a process made famous by Toyota. Although the concept of pull is covered, there is no chapter on Kanban or examples of calculations or Kanban cards. Thankfully, there are many references and other books available on this topic.

How should I read this to get the most out of it?

The book can be read straight through. For an experienced lean practitioner, it can easily be used as a reference book. Topics are well organized and tools are easy to find with a well-documented index. For example, if you want an example of an A3 Report, you will find many pages of explanation about the tool and how to use you. You will also find fully completed examples of the tool. This is extremely helpful and adds to the book's value as a practical reference.
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Most Recent Customer Reviews

5.0 out of 5 stars This book is good if you know a trick about it (kindle)
I tentatively downloaded this book for a class I am taking. I was a little nervous because I didn't think there would be any images. Read more
Published 1 month ago by derek johnson

5.0 out of 5 stars Thanks David
Can you imagine not only purchasing an excellent book on management, but even meeting the author and receiving an excellent education on the principles of that book. Read more
Published 12 months ago by Roberto J. Garcia

5.0 out of 5 stars The focus is on providing a practical guide for implementing Toyota's 4Ps...
This is a great book written by people who worked with Toyota manufacturing...It is filled with many examples, tools and templates which show how Toyota's production system works... Read more
Published 12 months ago by James William Martin

5.0 out of 5 stars Great "How To" Book for introducing TPS in a company
Our company is introducing Toyota Production System methodologies, and we all had questions about "Why do we use 11x17 paper for presentations? Read more
Published 21 months ago by David C. Goetz

5.0 out of 5 stars Deeper understanding of Toyota Way
I thought this book did a nice job of describing not only the "tools and techniques" that US mfgs try to copy from Toyota, but also the underlying culture of excellence and... Read more
Published 22 months ago by T. Nettleman

5.0 out of 5 stars The most important 'lean' book.
Simply the most important book to have on your shelf if you are serious about lean manufacturing. This book is less about theroy and more about practical advice. Read more
Published on February 13, 2008 by Randy Koser

5.0 out of 5 stars Spectacular
This is a must read and reference book for any lean implementer. After reading the Toyota Way I wondered how the Fielbook could be any better or even the same. Read more
Published on January 2, 2008 by C. Garza

4.0 out of 5 stars Excellent Training / Front-Line Leader Resource
I added this book to my lean collection over a year ago. Those of us that have 10+ years experience with lean, we will find this resource very basic. Read more
Published on November 9, 2007 by Joseph R. Tomaskovic

5.0 out of 5 stars Excellent Book
I recommend this book for anyone irrespective of the maturity level they are with lean implementation. Read more
Published on October 24, 2007 by meetsethu

4.0 out of 5 stars Toyota Way Fieldbook
Great addition to the Toyota Way book. Includes interesting tools to help implement and sustain principles.
Published on October 9, 2007 by D. Chan

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