Tag Archives: Japan

How to Develop Products like Toyota

Sobek also says Toyota tends to stay as flexible as possible until relatively late in the development stage. He cites as an example Toyota’s practice of leaving manufacturing tolerances to be set by die makers rather than by design engineers creating the prints. Die makers make die dimensions as close as practical to those in the CAD database, but have the flexibility to modify them so body parts fit together well. Manufacturing engineers then set tolerances around manufacturing capabilities.
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“Test first, then design. First run simulations and understand where the boundaries of solutions lie. Once you understand the alternate spaces between competing choices, you narrow the options in what are called integrating events.”

Integrating events are an opportunity to eliminate weak opportunities. It is only after these events are complete that detailed design commences. “The point is that you don’t get to detailed design until everything works,” says Kennedy. “That is the reason Toyota focuses so intently up front on understanding trade-offs.”

This is very similar to agile software development practices. Though due to different processes, software versus car manufacture the two process are not identical.

Though Toyota is adept at developing products, it may be a mistake to adopt its practices wholesale, no matter how good they are. “Much of the lean community tries to crow-bar Toyota’s approach into their own very different business model,”

This is always true. Copying what others do does not work. You can learn from others by understanding the benefits of their process and then adapting the ideas to your organization.

Toyota has several tools that help its engineers organize the tasks at hand. One of the most well known is called the A3 document, named for the size of the paper its information is written on. An A3 holds a distillation of project goals and customer wants. During development, it can serve as a crib sheet for engineers as they set priorities and make trade-offs. “A3s enforce the plan-do-check- act methods of quality,” explains Kennedy. “The A3 becomes the basis for Toyota’s entire review process.”

On my management improvement blog I discuss the Toyota Production System often, you can follow those posts if you are interested.

Engineers Rule at Honda

Engineers Rule, 2006

Of all the bizarre subsidiaries that big companies can find themselves with, Harmony Agricultural Products, founded and owned by Honda Motor, is one of the strangest. This small company near Marysville, Ohio produces soybeans for tofu. Soybeans? Honda couldn’t brook the sight of the shipping containers that brought parts from Japan to its nearby auto factories returning empty. So Harmony now ships 33,000 pounds of soybeans to Japan.
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Longtime auto analyst John Casesa, who now runs a consulting company, says, “There’s not a company on earth that better understands the culture of engineering.” The strategy has worked thus far. Honda has never had an unprofitable year. It has never had to lay off employees.

I checked and Honda was also profitable in 2007 and 2008 fiscal year (ending in September).

Friday Fun: Chimpanzee and Segway

Chimpanzee learning to ride a Segway on Japanese game show.

59 MPG Toyota iQ Diesel Available in Europe

image of seating in the toyota iQ

59 MPG Toyota iQ On Sale In Europe, US Plans Unclear

With lower carbon dioxide emissions than the Prius — around 159 grams of CO2 emitted per mile by the 1.0 liter gas engine and 166 g/mile for the diesel version — not only does the iQ deliver on fuel economy, but its straight-up conventional engine is a pollution winner too.
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At just about 9.8 feet long, 5.5 feet wide and 4.9 feet tall, Toyota certainly has pulled of a near engineering miracle with the amount of stuff they’ve crammed into this tiny vehicle. Toyota claims the iQ can fit 3 adults and 1 child “comfortably.”
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Toyota expects to sell about 80,000 of them a year in Europe.

I own some Toyota stock (and bought a bit more recently) based on their excellent management and production system and the results they have achieved (so I pay attention to what they are doing – plus I own them because they do things I see as wise so it is a self reinforcing dynamic). Business week recently wrote about Ford’s 65 mpg Diesel Car the U.S. Can’t Have.

I owned Ford stock back when they were adopting Deming based management principles but when they dropped those to pursue short sighted goals and poor management practices I sold and bought Toyota (turned out to be a very wise decision – my mistake was holding Ford too long hoping they would realize their mistake).

Toyota Engineering Development Process

Kenji Hiranabe talks about Toyota’s development process (webcast). Kenji shares a presentation he attended earlier this year by Nobuaki Katayama, a former Chief Engineer at Toyota, and the lessons he learned from him.

The webcast takes awhile to get going. If you are impatient you might want to start at the 6 minute mark. Some thoughts from the talk:

The Voice of the Customer is diffuse. A strong concept (for a project – new car for example) is very important to focus thought, listening to voice of the customer is important but must use strong concept to avoid losing focus (due to diffuse customer feedback).
Honest face to face communication is important. Bad news first – present bad news first [don’t try to hide bad news – my thoughts in brackets, John Hunter].
Everyone must think about cost reduction, many efforts add up to big impact [the importance of reducing waste everywhere].
benchmark, not to copy others, but to learn from what others do well.

The webcast includes a nice (though short) discussion of agile management in software development and lean manufacturing (the different situation of manufacturing versus software development). Kenji Hiranabe has also translated several agile and lean books into Japanese including Implementing Lean Software Development.

Best Research University Rankings – 2008

The annual ranking of research Universities are available from Shanghai’s Jiao Tong University. The methodology values publications and faculty awards which provides a better ranking of research (rather than teaching). Results from the 2008 rankings of Top 500 Universities worldwide, country representation of the top schools:

location	Top 100	% of World Population	% of World GDP	% of top 500
USA	54	4.6%	27.2%	31.6%
United Kingdom	11	0.9	4.9	8.3
Germany	6	1.3	6.0	8.0
Japan	4	2.0	9.0	6.2
Canada	4	0.5	2.6	4.2
Sweden	4	0.1	0.8	2.2
France	3	0.8	4.6	4.6
Switzerland	3	0.1	0.8	1.6
Australia	3	0.3	1.6	3.0
Netherlands	2	0.2	1.4	2.4
Denmark	2	0.1	0.6	0.8
Finland	1	0.1	0.4	1.2
Norway	1	0.1	0.7	0.8
Israel	1	0.1	0.3	1.2
Russia	1	2.2	2.0	0.4
China		20.5	6.6	6.0
India		17.0	1.9	0.4

There is little change in most of the data from last year, which I think is a good sign, it wouldn’t make much sense to have radical shifts over a year in these rankings. Japan lost 2 schools in the top 100, France lost 1. Denmark (Aarhus University) and Australia (University of Sydney) gained 1. Last year there was a tie so there were 101 schools in the top 100.

The most dramatic data I noticed is China’s number of top 500 schools went from 14 to 30, which made me a bit skeptical of what caused that quick change. Looking more closely last year they reported the China top 500 totals as (China 14, China-Taiwan 6 and China-Hong Kong 5). That still gives them an impressive gain of 5 schools.

Singapore has 1 in the 102-151 range. Taiwan has 1 ranked in the 152-200 range, as do Mexico, Korea and Brazil. China has 9 in the 201-302 range (including 3 in Hong Kong). India has 2 in the 303-401 range.

University of Wisconsin – Madison is 17th again 🙂 My father taught there while I grew up.
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USA Broadband is Slow. Really Slow.

Surprise, surprise: U.S. broadband is slow. Really slow.

The U.S. comes in 15th on a worldwide scale, far behind the leaders Japan, South Korea and Finland.
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A file that takes four minutes to download in South Korea would take nearly an hour and a half to download in the U.S. using the average bandwidth. Japanese users leaves U.S. users behind with an eye-popping 63.60 Mb/s download link. This means that Japanese can download an entire movie in just two minutes, as opposed to two hours or more here in the U.S. Just in case you are wondering: No, Japanese users do not pay more for their broadband connections. In fact, U.S. broadband cost is among the highest in the world.

Japan dominates international broadband speed with a median download speed of approximately 63 Mb/s, more than enough to stream DVD-quality video with surround audio in real time. Next on the list is South Korea where download speeds achieve an average of 49.50 Mb/s. Finland and France follow with 21.70 Mb/s and 17.60 Mb/s, respectively. Canada ranked eighth with an average download speed of 7.60 Mb/s. The U.S. came in 15th with 2.35 Mb/s.

I see this as an economic issue. Countries that have provided an investment in internet infrastructure to provide broadband to the home at reasonable prices will be rewarded.

Toyota Winglet – Personal Transportation

Winglet Personal Mobility Device from Toyota

Toyota has a long term vision. The population of Japan is aging rapidly. Toyota has invested in personal transportation and personal robotic assistance for quite some time. I must admit this new Winglet doesn’t seem like an incredible breakthrough to me (their earlier iUnit seems much better to me – though I am sure much more expensive too). The interest to me is in their continued focus on this market which I think is a smart move. The aging population worldwide (and others) will benefit greatly from improved personal mechanical assistance.

The Winglet is one of Toyota’s people-assisting Toyota Partner Robots. Designed to contribute to society by helping people enjoy a safe and fully mobile life, the Winglet is a compact next-generation everyday transport tool that offers advanced ease of use and expands the user’s range of mobility.

The Winglet consists of a body that houses an electric motor, two wheels and internal sensors that constantly monitor the user’s position and make adjustments in power to ensure stability. Meanwhile, a unique parallel link mechanism allows the rider to go forward, backward and turn simply by shifting body weight, making the vehicle safe and useful even in tight spaces or crowded environments.

Toyota plans various technical and consumer trials to gain feedback during the Winglet’s lead-up to practical use. Practical tests of its utility as a mobility tool are planned to begin in Autumn 2008 at Central Japan International Airport (Centrair) near Nagoya, and Laguna Gamagori, a seaside marine resort complex in Aichi Prefecture. Testing of its usefulness in crowded and other conditions, and how non-users react to the device, is to be carried out in 2009 at the Tressa Yokohama shopping complex in Yokohama City.

Toyota is pursuing sustainability in research and development, manufacturing and social contribution as part of its concept to realize “sustainability in three areas” and to help contribute to the health and comfort of future society. Toyota Partner Robot development is being carried out with this in mind and applies Toyota’s approach to monozukuri (“making things”), which includes its mobility, production and other technologies.

Toyota aims to realize the practical use of Toyota Partner Robots in the early 2010s.

On a personal note, I bought some more Toyota stock last week. The stock has declined a bit recently. Toyota is one of the companies in my 12 stocks for 10 years portfolio.

New Iron Based Superconductors

Research Suggests Novel Superconductor Is in a Powerful Class All its Own

discovered surprising magnetic properties in the new superconductors that suggest they may have very powerful applications — from improved MRI machines and research magnets, to a new generation of superconducting electric motors, generators and power transmission lines. The research also adds to the long list of mysteries surrounding superconductivity, providing evidence that the new materials, which scientists are calling “doped rare earth iron oxyarsenides,” develop superconductivity in quite a new way
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Early this year, Japanese scientists who had been developing iron-based superconducting compounds for several years, finally tweaked the recipe just right with a pinch of arsenic. The result: a superconductor, also featuring oxygen and the rare earth element lanthanum, performing at a promising -413 degrees F (26 K). The presence of iron in the material was another scientific stunner: Because it’s ferromagnetic, iron stays magnetized after exposure to a magnetic field, and any current generates such a field. As a rule, magnetism’s effect on superconductivity is not to enhance it, but to kill it.

Iron based superconductors might resist magnetic fields over 100 Tesla

The new superconductors seem like they will be able to make improved MRI machines and research magnets, a new generation of superconducting electric motors, generators and power transmission lines. Tesla is a unit of magnetic field strength; the Earth’s magnetic field is one twenty thousandth of a tesla.

Honda Engineering

Inside Honda’s brain by Alex Taylor III

why is Honda playing with robots? Or, for that matter, airplanes? Honda is building a factory in North Carolina to manufacture the Hondajet, a sporty twin-engine runabout that carries six passengers. Or solar energy? Honda has established a subsidiary to make and market thin-film solar-power cells. Or soybeans? Honda grows soybeans in Ohio so that it can fill up cargo containers being shipped back to Japan. The list goes on. All this sounds irrelevant to a company that built some 24 million engines last year and stuffed them into everything from cars to weed whackers.
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On fuel cells, Honda is literally years ahead of the competition. The FCX Clarity will go on sale in California this summer. It is powered by a fuel cell that uses no gasoline and emits only water vapor. Though mass production is at least a decade away, the Clarity is no mere test mule. Elegant and efficient, its hydrogen-powered fuel-cell stack is small enough to fit in the center tunnel – a significant improvement over other, bulkier power packs – and robust enough for a range of 270 miles.

The wellspring of Honda’s creative juices is Honda R&D, a wholly owned subsidiary of Honda Motor. Based in Saitama, west of Tokyo, R&D engineers create every product that Honda makes – from lawn mowers to motorcycles and automobiles – and pursue projects like Asimo and Hondajet on the side. Defiantly individualistic, R&D insists on devising its own solutions and shuns outside alliances. On paper it reports to Honda Motor, but it is powerful enough to have produced every CEO since the company was founded in 1948.
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The engineer in Fukui [Honda’s president and CEO] cannot help but be intrigued by what his former colleagues are up to, and his office is only a few steps away from Kato’s. But even with the CEO just down the hall, says Kato, “We want to look down the road. We do not want to be influenced by the business.”
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Honda allows its engineers wide latitude in interpreting its corporate mission. “We’ve been known to study the movement of cockroaches and bumblebees to better understand mobility,” says Frank Paluch, a vice president of automotive design. Honda R&D gets about 5% of Honda’s annual revenues. Most of the money goes to vehicle development, not cockroach studies
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mistakes like the Insight are also the exception. R&D has provided Honda with a long list of engineering firsts that consumers liked, including the motorcycle airbag, the low-polluting four-stroke marine engine, and ultralow-emission cars.