part of the reason, says the author, is that imitators fail to recognize the underlying principles of the toyota production system (tps), focusing instead on specific tools and practices. by the third day, he was able to see the more subtle impact of a new production layout on the worker’s movements. he also gave dallis resources he needed to act quickly—such as the help of a worker who moved equipment and relocated wires so dallis could test as many ideas as possible. it would take more than three months before he even arrived at the plant in which he was to be a manager. he would make changes to try to solve the problems he had observed and then evaluate those changes. in dallis’s second six weeks, he and his team were able to restore availability back to 90%, but this was still below the 95% target. however, takahashi was concerned that dallis still took too much of the burden on himself for making changes and that the rate at which he was able to test and refine improvements was too slow.
was there a better layout that would reduce the number of steps and time? dallis quickly realized that people at all levels, even those subordinate to the one for which he was being developed, were expected to structure work and improvements as experiments. in his meetings with takahashi at the u.s. engine plant, for example, he was required to propose hypotheses on monday and the results of his experiments on friday. but in the eyes of a toyota manager like takahashi, such a result would indicate that the manager didn’t fully understand the work that he was trying to improve. to ensure that dallis received the practice he needed and that he internalized his understanding of it, takahashi structured dallis’s training so that the complexity of his experiments increased gradually. for instance, the team realized that it had difficulties in keeping track of what work needed to be done and in identifying problems as they occurred. nevertheless, any company that develops and implements a training program such as the one dallis participated in is sure to reap enormous dividends.
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