Lean | Keeping idle workers busy at Toyota

Lean states that your management decisions should be based on a long term philosophy, even at the expense of short term financial goals.

But how does Toyota, mother of Lean principles, apply these rules in financial uncertain times? Times where car manufacturing is dropping all over the world and workers need to be laid off.

The Wall Street Journal wrote an article on how workers are kept at the plant, not send home or fired when there isn't any work for them for a while. The employees spend their days in training sessions designed to sharpen their job skills and find better ways to assemble vehicles.

Some article abstracts...

Toyota is using the down time to hone its workers??? quality-control and productivity skills. The company has pledged never to lay off any of its full-time employees, who are nonunion...

Jim Lentz, president of Toyota Motor Sales, the company???s U.S. sales unit, said the company believes keeping employees on the payroll and using the time to improve their capabilities is the best move in the long run. ???It would have been crazy for us to lose people for 90 days and [then] to rehire and retrain people and hope that we have a smooth ramp-up coming back in,??? Mr. Lentz said...

In Princeton, senior plant manager Norm Bafunno said he can already see the benefits of the training. Mr. Bafunno cites a Teflon ring designed by an assembly worker during the down time that helps prevent paint damage when employees install an electrical switch on the edge of a vehicle???s door...

Mr. Mason, a 40-year-old former firefighter, added: ???One of the major things that everyone is grateful for is that they thought enough of us to keep us here"...

Toyota continues to show intelligence, long term thinking and respect for people in their management decisions.