In 1957, Toyota was an underdog in the U.S. market.
By 1975, they dethroned Ford and Chrysler to become the #1 import brand.
Their secret? Giving every worker the POWER to stop a multimillion-dollar production line.
Here’s how Toyota rewrote the rules of manufacturing:
Toyota was struggling to catch up to American automakers.
So much so that their estimated losses in the initial 3 years were over $1.5 million; they lost $300-500 dollars on EVERY vehicle.
They needed to improve efficiency, reduce defects, and cut down on wasted resources.
The Andon Cord system was introduced by Taiichi Ohno, the father of the Toyota Production System.
Ohno believed that empowering frontline workers to stop the production line would lead to immediate problem-solving, higher quality, and continuous improvement.