The Toyota Way of Dantotsu (Radical) Quality Improvement: A Deep Dive into Extreme Quality Enhancement

When it comes to quality improvement, few methodologies are as revered as those pioneered by Toyota. In "The Toyota Way of Dantotsu Radical Quality Improvement," Sadao Nomura, a veteran of Toyota Motor Corporation, details his revolutionary approach that not only transformed Toyota's global operations but also set a new standard for excellence in the industry.

Background and Context

In 2006, TL&F (Toyota Logistics & Forklift) enlisted Nomura to assist with quality improvement at three global operations acquired in the U.S., Sweden, and France. These operations were struggling with quality issues, and Nomura's intervention was expected to bring about significant improvements. What transpired, however, was beyond anyone's expectations. The "Dantotsu" approach, which translates to "extreme," "radical," or "unparalleled" in Japanese, resulted in quality improvements that were so impactful, they were later adopted by Toyota's parent operations in Japan​ (Barnes and Noble)​​ (Routledge)​.

The Core of Dantotsu Quality Improvement

Nomura's methodology centers around an eight-step procedure designed to prevent the recurrence of quality defects. This procedure emphasizes immediate and thorough investigation of defects, implementation of countermeasures, and a standardized approach to defect management across all levels of the organization.

Here is a breakdown of the eight steps:

1. Actual Defect Check: Immediate examination of defective parts by team leaders to identify the process where the defect occurred.
2. Stock Check and Sorting: Determining if other parts have the same defect and identifying the defect's onset and duration.
3. Cause Investigation: Conducted through a "genchi genbutsu" approach, where team leaders go to the actual location to investigate the problem.
4. Countermeasure Implementation: Immediate implementation of countermeasures against the defect's causes.
5. Asaichi Report: Explanation of the causes and measures during morning meetings to ensure all team members are informed.
6. Standardization and Horizontal Deployment: Developing or revising work standards to prevent recurrence and implementing these standards across similar processes.
7. Education and Training: Training team members on the new standards to ensure correct implementation.
8. Daily Management: Ongoing checks by team leaders to ensure compliance with the standards​ (Lean Enterprise Institute)​​ (Routledge)​.

Impact and Results

The results of implementing Nomura's approach were nothing short of remarkable. For example, one U.S. plant saw a 90% reduction in defects in finished vehicle inspections within two years. This drastic improvement catapulted the company's performance to new heights, with production increasing from 4,000 units in 2008 to 22,000 units in 2019, all within the same manufacturing footprint​ (Lean Enterprise Institute)​.

Broader Applications and Legacy

Nomura's techniques have been applied not only to manufacturing but also to other areas such as distribution and supplier management, showcasing the versatility and effectiveness of his methods. The book details various real-world examples and provides a comprehensive guide for organizations aiming to achieve similar results.

Conclusion

"The Toyota Way of Dantotsu Radical Quality Improvement" is more than just a manual for quality improvement; it is a testament to what can be achieved with a relentless pursuit of excellence. Nomura's methods demonstrate that even the best organizations can reach new heights by embracing radical, structured, and thorough approaches to quality management. For anyone serious about quality improvement, this book is a must-read.

As President and co-founder of The Method Solutions, I was trained by Nomura-san over the course of two years, initially being scrutinized by him for my, less-than-ideal, presentations, but ultimately becoming a trusted student after many training sessions, including watching him course correct and improve several suppliers in the U.S. and overseas.   I now bring that experience and those teachings to my clients helping them to understand how to improve quality and reduce costs both internally and throughout their supply chain.

Schedule your no obligation introductory call today and start on the journey to dantotsu (radical) improvements!