Switching out the dies
The Japanese car companies began to run circles around Detroit in the 1970s. They didn’t outspend us or apply better technology - they focused on continual improvement.
They worried about more than improved quality. The Japanese engineers thought about how to make it easier to improve quality.
One typical example was a focus on switching out dies - massive hunks of metal that bash sheet steel into doors, hoods, and fenders. Want to fix a problem caused by a bad die? That will cost you three days in assembly line down time. Of course, dies were rarely switched out.
Toyota concentrated on switching out dies quickly - an activity that has no direct benefit for the consumer. They tried many ideas and eventually brought change times down to a minute (it’s now called Single Minute Exchange of Die).
Then the customer started getting benefits. Fixing problems was no longer painful, and quality shot up.
It’s the same in software or in banking. Process matters. Make it easy to fix problems and quality moves up. Read more »
Comments(3)








