Kaizen & Problem Solving
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In-depth guides
These are the original training documents. For the complete, current explanation — definitions, practice, and common mistakes — see the guides:
A 15-hour Toyota-style kaizen skills course in five three-hour sessions, assembled with help from Isao Kato: the six-step kaizen process, current state analysis, workplace observation, idea generation, and kaizen planning.
A two-volume handbook on Total Quality Management and Quality Control Circles produced by the Development Bank of Japan and the Japan Economic Research Institute for the Japan Program of the Inter-American Development Bank, published October 2003. Volume I explains what TQM and QCC are for managers, including quality assurance, TQM history, and the QC Story. Volume II is the practical guide for facilitators and circle leaders, covering how to start circle activities, the Seven QC Tools, and QCC techniques such as brainstorming, why-why analysis, and 5S.
A 104-slide training presentation on the 8 Step Problem Solving Method from the University of Kentucky Lean Systems Program, copyrighted jointly with Toyota Motor Engineering & Manufacturing North America (TEMA). It opens with guiding principles, then teaches the eight steps from clarifying the problem through standardizing successful processes, mapped to PDCA, covering temporary measures versus countermeasures, root cause analysis, and the A3 report as the communication format.