Problem statement:
With the rapid expansion of production Toyota was not able to establish the appropriate engineering skills and staff to support it. This demonstrated a breakdown in the internal communication policy within Toyota to the North American region. Business planning processes and communication from leadership on production goals where not aligned. This caused for rapid expansion without an adherence to quality standards in order to meet expansion initiatives within the North American market.
Business objective: Increase size of North American market
Business objective: Increase size of North American market
Cause and Effect:
Escalated hiring rate
Escalated hiring rate
Increased product output
Increased product output

Employees not properly trained
Employees not properly trained
Escalated time frame of production
Escalated time frame of production
Reduction in quality of product to North America
Reduction in quality of product to North America Non adherence to TPS guidelines
Non adherence to TPS guidelines

Poor quality in material received from suppliers
Poor quality in material received from suppliers

Note: for this assessment I will not consider a through investigation into the implementation of quality validation steps within the vendors. The assumption is that the vendor has agreed to comply with TPS standards.

Flow Chart after change:

Tools and techniques for collecting Data:
The TMC review process will offer a thorough review of batch quality against the TPS standards. In order to ensure quality a batch must receive a passing grade on the TMC audit checklist. This form must be completed and signed off by departmental leadership before being released to local distribution centers. This additional review step would provide an opportunity to implement changes in operating volume and grant greater the flexibility to