Latest / The Operator's Manual with Fexingo: Daily Decisions, Tactical Wins, and Business Execution
How Toyota Won With One-Piece Flow
Episode 37 of The Operator's Manual dives into Toyota's one-piece flow manufacturing philosophy—a shift from batch production that cut defects by 80% and slashed lead times from weeks to hours. Lucas and Luna walk through the 2011 Tohoku earthquake and tsunami, when Toyota's supply chain was disrupted, but its continuous-flow systems enabled faster recovery than competitors. They explore the specific case of Toyota's Kamigo plant, where engine production switched to single-unit flow in the 1950s, and contrast it with Ford's massive batch model. The hosts also break…
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