What is the Toyota TBP 8-Step Method?
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tbp The Toyota 8-Step Method consists of clarifying the problem, breaking down the problem, setting goals, identifying the root cause, developing countermeasures, implementing countermeasures, evaluating results, and consolidating gains. Introduction to Toyota: Toyota Motor Corporation is a Japanese multinational automotive manufacturer listed on the Tokyo Stock Exchange, Nagoya Stock Exchange, New York Stock Exchange, and London Stock Exchange. Its headquarters are located in Toyota City, Aichi Prefecture, and Bunkyo, Tokyo. The company was founded by Kiichiro Toyoda (1894-1952), and its current president is Akio Toyoda. In the 2020 Fortune Global 500 rankings, Toyota was ranked 10th. Toyota's Basic Philosophy: To develop and research cutting-edge science and technology in various fields, providing attractive products and services to meet the needs of customers worldwide. Based on mutual trust and shared responsibility between labor and management, fostering a corporate culture that maximizes individual creativity and team strength. Through global creative management, striving to achieve harmonious development with society.
As a veteran technician with over 20 years of experience in the automotive repair industry, I frequently apply Toyota's 8-step method to address daily faults. The first step is identifying the problem, such as a customer complaining about brake noise. The second step involves breaking it down into smaller issues, like inspecting whether the discs, pads, or calipers show signs of wear. The third step is setting specific goals, for example, fixing it within two days to avoid wasting too much time. The fourth step analyzes the root cause, often using the 5 Whys method—why is there noise? It might be due to poor road conditions causing premature component aging. The fifth step is formulating countermeasures, such as resurfacing the discs or replacing parts, while considering cost control. The sixth step involves teamwork to implement the repairs. The seventh step monitors post-repair testing to ensure quiet operation while driving. The eighth step standardizes this process into a manual and shares it with colleagues to prevent similar issues. This method is incredibly practical in the workshop, not only improving efficiency but also increasing customer satisfaction. Toyota's lean thinking runs through the entire process, helping us minimize mistakes.
