The Toyota Way

From a recent New York Times magazine article on Toyota and The Toyota Way, on their approach to designing the new Tundra pickup truck:

When I spoke not long ago with the Tundra’s chief engineer, Yuichiro Obu, and its project manager, Mark Schrage, both of whom work in Ann Arbor, they characterized their research for the Tundra as quite unlike what was done for the Sienna. For starters, designing a full-size pickup truck for the American worker is more complex than designing a van for a soccer mom. The way a farmer uses a truck is different from the way a construction worker does; preferences in Texas (for two-wheel drive) differ from those in Montana (for four-wheel drive). Truck drivers have diverse needs in terms of horsepower and torque, since they carry different payloads on different terrain. They also have variable needs when it comes to cab size (seating between two and five people) and fuel economy (depending on the length of a commute). In August 2002, Obu and his team began visiting different regions of the U.S.; they went to logging camps, horse farms, factories and construction sites to meet with truck owners. By asking them face to face about their needs, Obu and Schrage sought to understand preferences for towing capacity and power; by silently observing them at work, they learned things about the ideal placement of the gear shifter, for instance, or that the door handle and radio knobs should be extra large, because pickup owners often wear work gloves all day. When the team discerned that the pickup has now evolved into a kind of mobile office for many contractors, the engineers sought to create a space for a laptop and hanging files next to the driver. Finally, they made archaeological visits to truck graveyards in Michigan, where they poked around the rusting hulks of pickups and saw what parts had lasted. With so many retired trucks in one place, they also gained a better sense of how trucks had evolved over the past 30 years — becoming larger, more varied, more luxurious — and where they might go next.

Excellent.