Toyota, Lean Thinking, Pull, and the role of Religion

Toyota is the envy of much of the world, particularly the area near the "Big-three" auto manufacturers in Detroit, Michigan, USA.

Two very popular studies of Toyota's "secret" is the book Lean Thinking, by James Womack and Daniel Jones, and The Machine that Changed the World: The Story of Lean Production
by the same authors. The Lean Institute says:

In this landmark study of the automobile industry, Jim Womack, Dan Jones, and Daniel Roos explain lean production to the world for the first time, and discuss its profound implications for society. It is based on the largest and most thorough study ever undertaken in any industry: the MIT five-million-dollar, five-year, fourteen-country International Motor Vehicle Program’s study of the worldwide auto industry.

Philip Caldwell, Chairman and CEO, Ford Motor Company (1980-1985) had this to say about "Machine"

Truly remarkable.... The most comprehensive, instructive, mind-stretching and provacative analysis of any major industry I have ever known. Why pay others huge consulting fees? Just read this book.

The cover of "lean thinking" cmments:

Instead of constantly reinventing business models, lean thinkers go back to basics by asking what the customer really perceives as value.

It goes on to talk about terms such as value stream, flow, cycle, perfection, and pull.

It is the concept "pull" that I want to focus on in this post.

Womack says this (Chapter 4, page 67 of the 2003 revised edition)

Pull in simplest terms mans that no one upstream should produce a good or service until the customer downstream asks for it, but actually following this rule in practice is a bit more complicated. The best way to understand the logic and challenge of pull thinking is to start with a real customer expressing a demand for a product and to work backwards through all the steps required to bring the desired product to the customer.

Now, the authors have way more industrial experience than I do, with a mere MBA and most of an MPH, and a single "lean workshop" under my belt -- but I have my model to bring to bear on this question and raise some new ways to view pull. So I will be undaunted and proceed to offer some suggestions and reinterpretations of the same data for the reader's consideration.

First, in light of a multi-level approach to everything, we should realize that "customer" is not only plural in a horizontal sense (many drivers of vehicles), but in a vertical sense (the dealers, the supply chain, the auto industry, society, etc.)

Second, in light of feedback's description of everything in terms of closed process loops, not open-ended chains, we should complete the loop from the customer back to the company and look at how many times that loop will be travelled. (This is the "multiplier" of any "small" improvement we can make in the loop process.)

Third, in light of the multiple-scale, multiple-lens approach, we should move back ten paces and zoom the lens down so we see far more of the picture in space and time, and realize that customers often are repeat customers, or even lifetime customers. In that sense, not only does the satisfaction of this car matter, but it matters many times over in terms of the next cars this person, and their friends and family will buy the rest of their lives, and their children, etc.

Also, as we view Toyota over time, we have to note that the Toyota miracle, and the Honda miracle, started small, at about zero, competing with a firmly entrenched US Auto industry. The approach used by Toyota was slow, patient, long-term focus combined with a focus on the needs of everyday people, poor people, people the workers could relate to, in a country demolished by World War II.

And, in context, we should realize that "product engineer" in Japan has the same cachet and social status as "aerospace engineer" or "rocket scientist" in the USA.

So, the context here is that the workers respected and cared about the customers, and the customers cared about and respected the workers.

Now, finally, we can look at "pull", not as a production scheduling technique with optimal mathematical qualities, but as a human caring mechanism that had the potential to shape, or drive the Toyota engine -- with money being second. The "work" had a role, in the minds of the workers, of connecting them to the customers, which was a desired state.

This is where the light of religion, we can speculate that two more effects come to play. One is illustrated by the motto of Boy's Town in the US:

He ain't heavy father, he's my brother!

The second is a story I've told before, probably made up but it touches a truth:

In the middle ages, a quality control specialist came to work on a production problem in a church being built. Some stonemasons were doing work that was not high quality and needed to be redone, and others were doing excellent work consistently. The specialist asked one of the poorer workers what he was doing, and the reply came "I'm building this wall." Then he asked one of the best workers what he was doing, and the reply came "I'm building a cathedral!"

What these stories suggest is that there is a driving force, and a shaping force, that dramatically alters the functioning of people - and it is related, surprise, to purpose and meaning of "the same" action. The quality and sustainability of a worker's efforts depends on what it is they believe they are doing, and what larger picture it fits into.

If this effect has a significant effect, it probably means that "the customer" isn't actually viewed as "a customer" by the worker, but is viewed instead as "a person." "If I do my job well, and everyone does their jobs well, then old Mr. Lee will be able to afford a car and visit his children and his ancestor's graveside!"

This kind of bouyancy can make heavy objects lighter, and "impossible tasks" suddenly possible. I'll relate this later to much research on the impact of such "psychology" on worker output, innovation, creativity, willingness to change or share, etc. It is more like lifting "heavy" objects in the water than in the air -- they have the same mass but much less weight. Being filled with this kind of "spirit" really does make a difference in hard-nose measured output.

Interesting. And kind of what religion has been urging us to do for centuries.

This view, or focus, or framework shifts what aspects of the "lean" technique are most important, and which aspects are just artifacts. It changes how the process looks and how it should be managed.

So, it should be evaluated to see if it holds up to a formal study.

I recall also one last item of interest. When the head of Toyota was first approached by Americans who wanted to learn about their production techniques, there was great concern by some that Toyota would lose its edge. He thought about this and finally said, basically "Let them come. The Americans will never be able to do this. They don't have the necessary spirit in dealing with each other."

We recall that W. Edwards Deming of Quality Control also had no luck getting his message heard by Americans, and finally went, by invitation, to Japan and gave all of Japan a 20 year lead on the US on such techniques. They weren't "secret" but they were "not hearable" by American management.

This factor needs to be considered as well, and the source of "resistance" to such ideas identified and rooted out, if this technique is to bloom and thrive here.