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Eiji Toyoda: Bard of Assembly Line

Publication: The Economic Times Delhi;Date: Sep 20, 2013;Section: World View;Page: 13

EijiToyoda:BardofAssemblyLine
MARYANNKELLER EijiToyodadiedonTuesdayattheageof100,almost30yearsafterretiringfromactivemanagementofToyotaMotor.Like AlfredSloanandHenryFordbeforehim,Toyodawasanengineerwhosevisiondominatedthecompanyinitsformativeyears andbeyond.HetransformedToyotaintoaglobalpowerhousewithmanagementandmanufacturingprocessesthattranscended theautoindustry.Wherewouldwebewithoutkanban,kaizen,muda,andkeiretsu,aswellasacronymslikeJIT(justintime), TQC(totalqualitycontrol),ZD(zerodefects),andTPS(ToyotaProductionSystem)?AlthoughTaiichiOhnoisknownasthe fatheroftheToyotaProductionSystem,Toyodaprobablydeservesmorecreditforitsdevelopment.Heencouragedhisteamto learnfromWEdwardsDeming,tostudytheFordproductionsystem,andtousedatatorefinemanufacturingprocesses. Toyodawasknownasagoodlistenerandsomeonewhowantedtohearthesuggestionsandopinionsoftheverycapableteam hebuiltaroundhim.Heunderstoodthatinternationalsuccesswouldcomewithaffordableanddurablecars,andunderhis direction,ToyotadevelopedtheCorolla,anameToyodapersonallyselected,andtheCamry.LaterhepushedToyotaintothe luxurycarsector.AtToyodasinsistence,thecompanytookitsfirst,hesitantstepstoproducecarsoutsideJapan.Toyota didntknowifitsproductionsystemcouldbereplicatedoverseas,anditwascautioustocommit,evenafterHondaMotorand NissanwerebuildingcarsintheUSToyodasanswerwasajointventurewithGeneralMotors,adecisionthatwasnot enthusiasticallyembracedwithinToyota,butoncehismindwasmadeup,therewasnochangingit.Toyodachallengedhis managementteamtoforgetheagreementwithGMandtoacceptGMsclosedFremont,California,assemblyplant.Fremont wasnotoriousforinferiorqualityandpoorlabourrelations,whichToyodasawasanopportunity.Iftheycouldsucceedthere, theycouldsucceedontheirownanywhere,hetoldexecutives.Evenwithoutautomation,Toyotawasabletobuildcarsinfewer personhoursthanGM,andwithqualitycomparabletoJapan.Inreachingdecisions,theonlythingsthatmatteredtoToyoda weregenbaproductionsiteorfactoryandgenbutsuproducts.HetookgreatpleasureinvisitingToyotaassemblyplants andthoseofthecompetition.Hecouldstandinthemiddleofaplantandlistenbythesoundalone,hecouldjudgehowwellit wasoperating. BloombergBusinessWeek

(FarLeft)EijiToyoda(Left)EijiToyoda,left,&GMChairmanRogerBSmithattheUnitedMotorManufacturingplantin California,thatwasToyotasfirststepintomanufacturingoutsideJapan

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