Join us at Toyota
Join The Lean Leadership Academy® for
Leading the Toyota daily management & Obeya system
February 6-8 (9), 2024
Exclusive Gemba walking tour and workshop
hosted by Toyota Material Handling, Columbus, IN
What our previous attendees are saying about this tour and workshop
“Lean Leadership Academy president, Sam McPherson and Toyota Leaders: Tom Lego and Scott Redelman were awesome and it was a joy to be part of the workshop; It was so engaging. I just want to thank you again for the training. It was a very good and useful tour and workshop; all of the explanations were clear. I understand the Obeya room much more now!”
“What a great learning opportunity from of the best leaders on the planet!
“The implementation of the daily management Obeya results in an immediate “Big Bang!” productivity improvement across all operations. As a result, Timken has implemented the Daily Management Obeya globally in over forty of our locations!”
Here are some of the companies and organizations
that have attended past tours and workshops:
Intel Corporation | The Timken Company | ADM – Archer-Daniels-Midland Company | JTEKT | Strum, Ruger, & Company (aka Ruger firearms) | Industrial Andons | American Greetings | Bridgewater Interiors | Applied Materials | Bell Nordic | HEC Montreal | Hasbro | U.S. Army Special Forces | JFK Special Warfare Center and School | Fives North America | Gemba Academy | Discover Finance| Hartford Healthcare | MossAdams
LEADING THE TOYOTA DAILY MANAGEMENT SYSTEM
TOYOTA GEMBA WALKING TOUR AND WORKSHOP
hosted by:
TOYOTA MATERIAL HANDLING
COLUMBUS, INDIANA
Dates
February 6 – 8, 2024 All Times are Eastern Time
February 9, Problem-Solving for Daily Management Workshop**
Locations
Toyota Material Handling, Rotunda, 5559 Inwood Drive, Columbus, IN
Costs
All Three Days:
Individual: $3500 per person
Groups of 2-5: $2500 per person*
Groups of 6 or more: $2000 per person
*Special Day 4: $500 per person ** for workshop tour attendees
Manufacturers and Groups of 2 or more will be prioritized.
*Special pricing available for Lean Leadership Academy Alumni and Clients; call for more information.
A cancellation occurring within two to four weeks of the tour and workshop dates will be given credit for attendance for a future tour and workshop within a year of the payment date. A cancellation occurring after two weeks will not be refunded.
To cancel, please call The Lean Leadership Academy at (910) 489-7688 or email workshop@theleanleadershipacademy.com
What You Will Gain
- Get a first-hand look at Toyota Operational Leadership in Action
- Speak to Toyota Leaders about their Roles, Routines, and Responsibilities
- Discover what Toyota and The Lean Leadership Academy looks for in Leaders and Team-members and how we train them
- See and discuss the Toyota Production System in Actions – Andons, Mixed Model Production, AGVs, sub-assembly lines, Kamishibai, Kanban, material handling, etc.
- See the Toyota Lean Management System in Action: Daily Management Obeya, Shop-floor management, Team Quality Circle Activities, Shop-Floor Management Boards, meet and speak with Toyota Operational Leaders, etc.
What you will take away:
- How to Lean and Manage your Lean System
- What to look for in your existing and future Lean Leadership
- How Toyota Leadership and Daily Management actually works
- How to develop your leadership pipeline
- How the Lean Leadership Academy makes Lean Leadership and Culture stick for years.
Who Should Attend
Anyone serious and committed to about restarting leading their Lean Transformation
Anyone who has struggled with their Lean Transformation or Lean efforts
- CEO’s, COO’s, Presidents, VP’s, Directors
- HR Leaders, Company Trainers, People Development Managers
- Plant Managers, Senior Managers, Operations Manager, CI Leaders, Shopfloor Leaders
Dates
February 6 – 8 (9), 2024 All Times are Eastern Time
WORKSHOP AGENDA OVERVIEW
*Agenda Subject to Change
DAY 1
Connecting the Hoshin to Daily Management Workshop
Location: Hampton Inn
Breakfast 7:00 – 7:45 am
Start Time: 8:00
Lunch Provided: 12:00 – 1:00 pm
Reflections on the Day: 4:30 – 5:00 pm
End Time: 5:00
Pizza Social: 6:30 – UTC pm
12161 North US 31, Edinburgh, IN, 46124
Phone: (812) 526-5100
Call Hotel for Discount
Use Code: Toyota Workshop
- Kick Off – Meet Your Toyota & Lean Leadership Academy Team
- Interactive Tour and Workshop Objectives
- Lunch and Learn (Lunch Provided)
- Social: 6:30 – UTC Hilton Garden Inn
- Introduction to Toyota’s Management Model Pyramid
- Introduction to Toyota’s Management Philosophy (MBO vs. EBM – Exception Based Management)
- Toyota Team Based Organization Leadership Model
- Introduction to Toyota’s Visualized Management System (The Obeya System)
- Overview of Hoshin Management and KPI and Sub-KPI Target Setting
- Toyota’s Five Missions
- Setting Up a Daily Management Obeya
- Setting the Prime Standard: The Daily/Shift Production Schedule
- Daily Obeya Simulation Exercise Part 1
DAY 2
Establishing a Daily Management Obeya Workshop
Location: Hampton Inn
Breakfast 7:00–7:45 am
Start Time: 8:00
Lunch Provided: 12:00–1:00 pm
Reflections on the Day: 4:30–5:00 pm
End Time: 5:00
Optional Fire-side Chat (Hilton Garden Inn)
- Making Daily Management Visual: “Proper Problem Awareness” at a Glance
- Leading the Toyota Production System
- Roles and Responsibilities of Toyota Leaders in Operations and Shop-floor Management
- The Role of Plant Leaders in the Adrenaline Room
- Establishing the Shift and Daily Production Schedule as the “Prime Standard”
- Heijunka and Seeing Your Problems Coming – Visual Management and Schedule Leveling
- Creating Flow with Weak Point Management
- Change Point Management at the Operations Level
- Daily Management and Problem Management
- Abnormality Management
- Managing Problem-Solving for Daily Management
- Floor Management & Development System – Making Floor Management Visible
- The Production Plant Manager
- The Production Operations Manager
- The Production Group Leader
- Optional: Sensei Fire-side Chat with Toyota Special Guest(s)
DAY 3
Toyota Gemba Walking Tour
Hosted by Toyota Material Handling
Leading Toyota Operations Workshop
Location:
Rotunda (see photo)
Toyota Material Handling, Inc. 5559 Inwood Drive Columbus, IN
Start Time: 8:00am
End Time: TBD
Lunch: Provided
- Introduction to Toyota Material Handling
- Toyota History Wall Tour
- Principles of the Toyota Way
- Overview of the Goals of TPS
- Gemba Walking and Study Tour of the Toyota Production System in Action
- Production Flow
- Kanban
- TPS Material Handling at Toyota
- The Andon System
- Floor presentation of Floor Management discussion with Toyota Leaders (FMDS)
- Overview of TMH’s Daily Management Obeya aka The Adrenaline Room by Toyota Leaders
- Deep-dive Q&A with TMH Leaders
- Introduction to FMDS
- Hands-On FMDS Exercise
Optional Day 4
Leading Problem-Solving at Toyota
Location:
Rotunda (see photo)
Toyota Material Handling, Inc. 5559 Inwood Drive Columbus, IN
Start Time: 8:00am
End Time: TBD
Lunch: Provided
- Leading Problem Solving at Toyota
- Toyota’s Problem Registration System
- The Four Types of Problems at Toyota
- Problem-Solving Activities at Toyota
- To A3 or Not to A3; that is the Question? The right tool for the Problem-Solving job
- Introduction to Toyota’s 8 Step Problem Solving-Process
- Problem-Solving for Daily Management
- Problem-Solving for Daily Management Exercise
- Managing Problem-Solving Timelines
- Managing Problem-Solving Activities
- Reflections and Monday Morning Plan
- Creating a Culture of Problem-Solvers with Quality Circle Activities
- Coaching Toyota Problem-Solving to develop Leaders.
- Reflections
About Toyota Material Handling
About Your Host
Toyota Material Handling
This workshop includes factory tour is hosted by Toyota Material Handling (TMH), the #1 manufacturer of fork trucks in North America and winner of Assembly Magazine’s Plant of the Year Award. Here’s what Assembly Magazine had to say about Toyota Material Handling.
Toyota has long been regarded as the gold standard for Lean manufacturing. TMH, located in Columbus, Indiana, is an especially valuable example of Mixed Model Manufacturing since the number of base models and level of customization far exceeds what is seen in the automotive sector. The three-day workshop and factory tour included in this workshop will dramatically support what you will learn in the classroom, and confirm the power and flexibility of Leading the Toyota Lean Management and Production System.
Toyota experts will also spend time during the workshop to answer any Toyota-specific questions that may come up during the tours or in the classroom.
Your Host Instructors:
Sam McPherson, President, The Lean Leadership Academy
Toyota Trained Toyota Lean Management System & TPS Transformation Coach | Award Winning International Speaker-Writer-Researcher on Leading on the subjects of Leadership, Lean Transformations, Lean Transformation, Enterprise and Operational Excellence, and Cultures of Excellence. Sam is a Shingo Institute Faculty Fellow.
Sam has worked with his first Japanese production plant as a line worker and later production, warehouse, and shipping supervisor. Sam was trained at Toyota Motor Manufacturing Kentucky as a Toyota Scholar from 1993 – 1995 and continues to work with Toyota and transforming Toyota Tier Two Suppliers to Tier One and Alternate suppliers close to three decades across a verity of industries. Sam has held manufacturing leadership roles from Plant Manager to Chief Operating Officer and President.
Tom Lego, Toyota Brand Ambassador, Toyota Material Handling
Thomas Lego works as a Brand Ambassador at Toyota Forklift, which is an Industrial Machinery & Equipment company with an estimated 1,454 employees; and founded in 2006. They are part of the Product Marketing team within the Marketing Department and their management level is Non-Manager. Thomas graduated from Indiana University – Kelley School of Business in 1982 and is currently based in Columbus, United States.
Scott Redelman, Director of Toyota Lean Management System Services
Internal and Dealer Consultant, Scott is Toyota leader with close to three decades of operational leadership at Toyota Material Handling, including, Business Strategy, Business Development, Production Control, and now leader TMH’s Toyota Lean Management Systems Team specializing in TPS “original lean” support for business partners and customers – regardless of industry! Enhancing organizational cultures by leveraging talent management and team building through lean leadership, strategic planning, and TPS tools. Strategic leader of Toyota Material Handling’s TPS journey. Impactful management consulting with customers in many industries: manufacturing, non-profits, logistics, health care, distribution, military, etc.
About Your Host
Toyota Material Handling
This workshop includes factory tour is hosted by Toyota Material Handling (TMH), the #1 manufacturer of fork trucks in North America and winner of Assembly Magazine’s Plant of the Year Award. Here’s what Assembly Magazine had to say about Toyota Material Handling.
Toyota has long been regarded as the gold standard for Lean manufacturing. TMH, located in Columbus, Indiana, is an especially valuable example of Mixed Model Manufacturing since the number of base models and level of customization far exceeds what is seen in the automotive sector. The three-day workshop and factory tour included in this workshop will dramatically support what you will learn in the classroom, and confirm the power and flexibility of Leading the Toyota Lean Management and Production System.
Toyota experts will also spend time during the workshop to answer any Toyota-specific questions that may come up during the tours or in the classroom.
Your Host Instructors:
Sam McPherson, President, The Lean Leadership Academy
Toyota Trained Toyota Lean Management System & TPS Transformation Coach | Award Winning International Speaker-Writer-Researcher on Leading on the subjects of Leadership, Lean Transformations, Lean Transformation, Enterprise and Operational Excellence, and Cultures of Excellence. Sam is a Shingo Institute Faculty Fellow.
Sam has worked with his first Japanese production plant as a line worker and later production, warehouse, and shipping supervisor. Sam was trained at Toyota Motor Manufacturing Kentucky as a Toyota Scholar from 1993 – 1995 and continues to work with Toyota and transforming Toyota Tier Two Suppliers to Tier One and Alternate suppliers close to three decades across a verity of industries. Sam has held manufacturing leadership roles from Plant Manager to Chief Operating Officer and President.
Tom Lego, Toyota Brand Ambassador, Toyota Material Handling
Thomas Lego works as a Brand Ambassador at Toyota Forklift, which is an Industrial Machinery & Equipment company with an estimated 1,454 employees; and founded in 2006. They are part of the Product Marketing team within the Marketing Department and their management level is Non-Manager. Thomas graduated from Indiana University – Kelley School of Business in 1982 and is currently based in Columbus, United States.
Scott Redelman, Director of Toyota Lean Management System Services
Internal and Dealer Consultant, Scott is Toyota leader with close to three decades of operational leadership at Toyota Material Handling, including, Business Strategy, Business Development, Production Control, and now leader TMH’s Toyota Lean Management Systems Team specializing in TPS “original lean” support for business partners and customers – regardless of industry! Enhancing organizational cultures by leveraging talent management and team building through lean leadership, strategic planning, and TPS tools. Strategic leader of Toyota Material Handling’s TPS journey. Impactful management consulting with customers in many industries: manufacturing, non-profits, logistics, health care, distribution, military, etc.
Phone: (812) 526-5100
Call Hotel for Discount
Use Code: Toyota Workshop
Hilton Garden Inn, Columbus/Edinburgh (Location of the Pizza and Beer Social)
Located directly behind the Hampton Inn
12210 N Executive Dr, Edinburgh, IN 46124
Phone: (812) 526-8600
Discount Code: Toyota
Other lodging options:
Holiday Inn and Suites, Columbus/Edinburgh $139 Address: 12225 N Executive Dr, Edinburgh, IN 46124 Phone: (812) 526-4919
Courtyard by Marriott: Address: 3888 Mimosa Dr, Columbus, IN 47201 Phone: (812) 342-8888
Airport:
Indianapolis International Airport (45 min drive)
7800 Col. H. Weir Cook Memorial Dr, Indianapolis, IN 46241
Get on I-70 E from Col. H. Weir Cook Memorial Dr
4 min (2.7 mi)
Follow I-70 E and I-65 S to US-31 N in German Township. Take exit 76B from I-65 S 41 min (45.2 mi)
Continue on US-31 N to your destination.
2 min (0.4 mi)
Edinburgh, IN 46124
Locations:
Hosted by Toyota Material Handling, Inc. 5559 Inwood Drive Columbus, IN
