Join us at Toyota
THE TOYOTA WAY TO LEAD AND MANAGE
PROBLEM-SOLVING CERTIFICATION TRAINING
April 1-3, 2025
TOYOTA GEMBA WALKING TOUR AND WORKSHOP
TOYOTA MATERIAL HANDLING
COLUMBUS, INDIANA
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
April 1-3. 2025, All Times are Eastern Time
Locations
Toyota Material Handling, Rotunda, 5559 Inwood Drive, Columbus, IN
Workshop Location, Hampton Inn Columbus/Taylorsville 12161 N US 31, Edinburgh , IN, 46124
Overview
Are you struggling with your Problem-Solving skills? Do you struggle with the timely resolution of Problem-Solving? Do you struggle will your leaders’ Problem-Solving Skills? Do struggle with creating the elusive Lean Culture?
Toyota is known worldwide for having the Gold Standard in Problem-Solving Cultures. This workshop is the most exhaustive Problem-Solving training outside of Toyota!
What You Will Learn & Experience
- First, you will see the Toyota Production System (TPS) live in action
- Toyota Classification of Problems
- Four Types of Problems at Toyota
- How Toyota Creates and Sustains a Culture of Engagement
- How to Manage Problems as part of Daily Management
- How to Connect Problem-Solving to Obeya Operations
- How to Lead, Coach, and Mentor Problem-Solving
- Speak with Toyota Leaders about Problem-Solving at Toyota
- See the Toyota Lean Management System in Action
- Speak with Toyota Leaders about Problem-Solving
- Learn about Jidoka and Abnormality Management and Control
- Toyota’s 8-Step Problem-Solving Process
- Toyota’s expected Mindset and Attitude towards Problem-Solving
- Toyota “real-life” examples of A3s, Structured 5 Why, A2, etc.
- How to Register and Manage Problems
- How to Lean, Coach and Mentor Problem-Solving
What you will take away
- Certificate of Training upon completion of Problem-Solving and Coaching Assignment and Exam
- Toyota Problem-Solving forms and examples
- Leading and Managing Problem-Solving Leaders Manual
- Laminated Problem-Solving Worksheet
- Problem-Solving TWI Styled “How-To” cards
- Problem-Solving Management and Tracking Documents
- Problem-Solving Matrix and Management Timetable Chart
- One-on-One Problem-Solving Coaching of your selected Problems
Who Should Attend
- Anyone who is committed to Leading, Teaching, Training, Coaching, and Mentoring Problem-Solving the Toyota Way
- Anyone serious and committed to creating a Culture of Highly Engaged Problem-Solvers
- Anyone struggling with Problem-Solving and Problem Management as part of their Lean Transformation or Lean efforts.
Costs
All Three Days:
Groups of 1-5: $2500 per person*
Groups of 6 or more: $2000 per person
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
Dates
February 4 – 6, 2025 All Times are Eastern Time
WORKSHOP AGENDA OVERVIEW
*Agenda Subject to Change
DAY 1
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
Use Discount Code: Toyota
- Kick Off – Meet Your Toyota & Lean Leadership Academy Team
- Introduction to the Toyota Production System
- Overview of Jidoka
- Introduction to Daily Management – Abnormality Management and Control
- Change Point Management – How Toyota avoids Problems
- Abnormality Management
- Weak Point Management
- How the Andon System Works
- The Roles of Leaders in Daily Management & Problem-Solving Management
- The Four Types of Problems at Toyota
- Problem Classification Exercise
- Problem Documentation and Reporting Requirements: When to use an A3 and when to use other Toyota Problem documentation
- Toyota’s Problem Registration System
- Overview of Graphics used in Problem-Solving
- Introduction to Toyota Business Practice (TBP): Toyota’s 8 Step Problem Solving Process
- Introduction to Toyota Problem-Solving Attitude and Mindset: Drive & Dedication
- Problem Type & Classification Exercise
- Toyota Problem Solving Exercise
- Reflections
- Social: 6:30 – UTC Hilton Garden Inn
DAY 2
Location: Toyota Material Handling, Inc. 5559 Inwood Drive Columbus, IN
Start Time: 8:00 am
End Time: 5:00 pm
Lunch: Provided
-
Introduction to Toyota Material Handling
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Toyota History Wall Tour
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Principles of the Toyota Way
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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 by Toyota Leaders
-
Kamishibai activities & Equipment Reliability
-
Overview of TMH’s Daily Management Obeya aka The Adrenaline Room
-
Deep-dive Q&A with TMH Leaders
-
How Toyota Creates a Culture of Highly Engaged Problems Solvers
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Toyota’s Engine for Leader Development – Quality Circle (Team Problem-Solving and Kaizen Activities) & Jishuken Activities (Management Development Problem-Solving Activities)
-
Weak Point Management in Production
-
Reflections
DAY 3
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
- Types and Effectiveness of Countermeasures
- Toyota Floor Management & Development System (FMDS) Exercise
- Preventing Problems at Toyota
- The Golden Rules of Shop-floor Management
- Introduction to Managing Problem-Solving Activities at Toyota
- Toyota’s Dispatch System and Problem Reporting Requirements
- Introduction to the use of the Problem-Solving Matrix
- Managing Problem-Solving Timelines
- Coaching Toyota Problem-Solving to develop Leaders
- How to use Toyota’s 8 Step Problem-Solving Coaching Guide
- How to use Toyota’s A3 & Structured 5 Why (aka 5C/A2) Coaching Guide
- Problem-Solving Coaching Exercise
- Tracking Problem-Solving Activities
- Verifying Countermeasures
- Validating Countermeasure Tracking
- Problem-Solving Closing Activities
- Reflections
About Your Host Instructors
Sam McPherson, President, The Lean Leadership Academy
Sam is the co-developer with Art Smalley of the Four Types of Problems and is a Toyota Institute Certified Trainer of Toyota Business Practice, Toyota’s Eight Step Problem Solving Process and Toyota Lean Management System framework. Sam, 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. Thomas graduated from Indiana University – Kelley School of Business in 1982 and is currently based in Columbus, United States.
About The Lean Leadership Academy
The Lean Leadership Academy was established in 2004 and provides expertise in developing Lean Organizational Leadership skills and prepares Senior Leadership teams to lead their organizations through a Toyota Lean Management System and TPS-based Lean transformation into a Lean Enterprise System and Functions, Lean Management Operating System, and Culture of Excellence.
About 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.
Locations:
Hosted by Toyota Material Handling, Inc. 5559 Inwood Drive Columbus, IN
Host Hotel and Workshop Location
Hampton Inn Columbus/Taylorsville
12161 North US 31, Edinburgh, IN, 46124
Phone: (812) 526-5100
Discount Code: Toyota
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
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