Toyota Business Practice (TBP) Problem Solving Training

Problem Solving as Daily Work

In a Lean environment, problem solving is not an exception — it is daily practice. Any gap between the current situation
and the ideal situation is seen as an opportunity to improve.

The focus is never on who caused the problem, but on why the problem exists.
Only by identifying the true root cause can a structural and sustainable solution be implemented.

The Role of Problem Solving in Kaizen

Toyota Business Practice (TBP) Problem Solving is a foundation of Kaizen — continuous improvement through small,
step-by-step advances starting at the shop floor.

This approach helps organizations to:

• Detect gaps between current and ideal situations across the workplace
• Actively involve employees in improvement
• Build motivation and ownership for better results
• Create continuous improvement as a company-wide culture

Eliminating Waste and Creating Customer Value

Problem solving in a Lean context is always linked to process improvement and value creation for the customer.
Anything that does not add value is considered waste (muda) and must be identified and eliminated.

This mindset applies in both profit and non-profit organizations — across manufacturing, office/service,
and healthcare environments.

Leadership, Gemba and Coaching

In Lean organizations, leaders spend significant time at the Gemba — the place where value is created.
Their role is not to provide answers, but to coach employees toward strong problem analysis and effective countermeasures.

Toyota Business Practice supports leaders to ensure problems are handled:

• At the right level
• By the right people
• Using the right method

The Toyota Business Practice Method

During this training, participants learn to tackle structural problems using the 8-step Toyota Business Practice method.
This method is executed through PDCA (Plan–Do–Check–Act).

PDCA provides the discipline to:

• Analyze the problem and understand its nature
• Identify the true root cause
• Test countermeasures before full implementation
• Implement and standardize improvements sustainably

A3 Thinking and Learning from Toyota Practice

The A3 analysis and reporting method is used throughout the training to structure thinking, build consensus,
and successfully complete the PDCA cycle. It is a powerful instrument for continuous improvement in both profit and non-profit organizations.

Participants learn these principles directly from a former Toyota Motor Europe Master Trainer, who connects theory and practice
through extensive real-world experience. Optional individual offline coaching can be provided after the training to support application.

After this training, participants are able to apply Toyota Business Practice (TBP) Problem Solving in a practical,
efficient and disciplined way—turning recurring issues into sustainable improvements.

• Work through the 8-step Toyota Business Practice method to tackle problems in a structured way in your own work environment
• Reframe problems as opportunities and make problem solving part of daily work
• Engage employees as a central part of the method—because their insight is critical to solving work-related issues effectively
• Strengthen fact-based analysis, root cause thinking and the discipline to follow through

Our trainers come from industry and bring extensive Lean experience. The training combines academic fundamentals with real-life practice through
in-depth examples, challenging case studies and hands-on exercises that test application—not just understanding.

Introduction to Toyota Business Practice (TBP)

The training starts with a clear introduction to Toyota Business Practice (TBP) and its role within the Lean way of working.
Participants learn how Toyota uses TBP as a structured method to tackle problems and how it forms the foundation of A3 thinking.

We explore how PDCA thinking is embedded in Toyota Business Practice and how this disciplined approach supports sustainable improvement.

The 8-Step Toyota Business Practice Method

Participants gain a detailed understanding of the 8-step Toyota Business Practice methodology and learn how each step contributes
to effective problem solving.

• What the 8 steps are and how they are logically connected
• How to apply the steps effectively in real work situations
• Illustration of the method using a practical, realistic example

A3 Thinking and Documentation

The A3 document is introduced as a central thinking, analysis and communication tool within Toyota Business Practice.

• How the A3 is structured
• How it supports PDCA thinking and consensus building
• How it is used as a living document throughout the problem-solving process

Exercise & Case Study

Participants work in groups on a hands-on case study to practice Toyota Business Practice Problem Solving.

• Applying the 8-step Toyota Business Practice method
• Analyzing a real-life problem using PDCA
• Creating a concise and visual A3 document as output

Tips, Pitfalls & Practical Guidance

The day concludes with practical insights based on real Toyota and industry experience.

• Common pitfalls when applying Toyota Business Practice
• Typical mistakes in A3 problem solving
• Practical tips to improve effectiveness and follow-through

Optional individual offline coaching is available after the training to support application in the participant’s own work environment.

Offices & Services

This training is ideal for professionals who want to improve administrative and service processes using a structured Lean approach.

• Middle and senior managers
• Office managers and team leaders
• Process owners and improvement leads
• Professionals aiming to apply Toyota Business Practice (TBP) Problem Solving to administrative workflows

Healthcare

Designed for healthcare professionals who want to improve care delivery and organizational performance through Lean thinking.

• Department heads and unit managers
• Quality, safety and prevention managers
• Healthcare leaders responsible for performance improvement
• Professionals applying Toyota Business Practice Problem Solving to patient care and hospital processes

Manufacturing & Supply Chain

Targeted at professionals who want to drive operational excellence by embedding structured problem solving in daily operations.

• Managers and operational leaders
• Continuous Improvement and Lean leads
• Engineers and supply chain professionals
• Motivated employees ready to improve efficiency, quality and customer satisfaction using Lean and Toyota Business Practice