We have just enjoyed a day of rest in Kyoto after many others of travel and visiting assembly plants, where the sheer pride and joy in “making things” is palpable. At first, some of us questioned how line operators remain engaged and focused in their work but we soon recognized why manufacturing is so valued in this culture. The Toyota spirit of being studious and creative is evident in each place we have visited. There is reciprocal respect between each worker and their commitment to improvement.

In these places it is so easy to see that when standard work and flow are in place the entire workplace is less chaotic. The workload is balanced and little needs to be said among the operators when one picks up where the other left off. Watching their teamwork is like watching a well choreographed ballet or a fantastic soccer game. We are in large factories but the environment is surprisingly serene. Similar to the airplane simulation, which many of us have experienced, people are not working harder or faster, just smarter. There is little chatter among the workers because there doesn’t need to be.

We have seen many innovative enhancements and realize that standard work and removing waste is the foundation for incremental improvement. Likewise, an organized environment is critical for flow. We have seen that having a space that is 5S’d does not necessarily guarantee flow, but it is clear that flow cannot be accomplished without it. This simple idea provides a starting place for all of us whether or not we are involved in RPIWs or focused program value streams.

Lastly, we have been struck by the impact of the economic crisis and the renewed emphasis on removing waste as the primary strategy for cost reduction. The scope of projects is kept small which allows the change to happen with little disruption to the line. We have seen examples where small improvement efforts occur in the moment through collaboration with members of their Kaizen Production Team (the equivalent of our CPI staff). We are challenged but optimistic about creating ways to expand CPI efforts and making CPI our daily work.

We are back on the bus and looking forward to the grand finale or the final minutes in overtime (choose your analogy) as we head towards Toyota City. I look around and see some tired faces but also a confirmation that this was worth every second…..

12 hours later… “Absolutely awesome” may be the only way to describe what we have seen at Toyota. Seeing the big picture, an example of true flow and the synchrony of assembly lines and materials has allowed us to envision what is really possible for our patients.

Mikhail Baryshnikov and the folks at the Federation International Football Association (FIFA) would be envious of what Toyota has accomplished. We also come away with a renewed commitment to make sure that our staff have all the resources they need (not more or less) at the right time and in the right place.

-Debra Gumbardo and The Transplant Team