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Posts Tagged ‘Toyota quality’

Silent Problems & Persistently Bad News

Monday, July 12th, 2010

One might wonder why Toyota has been consistently delivering bad news since the initial brake recall some 6-months ago? And how about the falterig economies in Europe like Greece and Spain. And what about all the stories related to the financial crisis like Lehman Brothers, Bear Stearns, Citi Group and others in recet years? Its almost as if there was pent up bad news once the initial story broke loose. Then once the floodgats opened, the torrent of bad news was overwhelming.

For instance, last week I was working with a client that had experienced a barrage of silent problems surfacing in recent months. To say the least, the many layers of bad news was taking its toll. On the surface, it felt as if the sky was falling. However in reality, there was a cleansing process underway. It was painful, yet necessary. An excellent story relating to this phenomenon is Toyota, who has experienced a multitude of quality related problems in 200. This past week they announced a 2nd recall in less than a month, this one for defective engine valve springs. A recent news story notes:

Toyota knew two years ago about the engine problem behind its latest Lexus recall, even changing the spring part to correct it, but did not think a recall was warranted until recently, a company official said Tuesday.

Toyota Motor Corp. started Monday a global recall over engine defects in its Lexus luxury models sold around the world, as well as the Crown sold in Japan, moving to repair some 270,000 vehicles to replace valve springs — crucial engine components that are flawed and could cause vehicles to stall.

In August 2008, Toyota changed that spring part, making it thicker, to prevent the problem, spokesman Hideaki Homma told The Associated Press. That is why the latest recall does not affect vehicles produced after August 2008.

What Toyota is experiencing today with the high volume of recalls is typical in many situations. What is really being exposed here is a system and culture oriented towards avoidance and neglect. And now that a new course has been set, the torrent of silent problems is being vetted all at once. However in the end, this will become positive if the problems aren’t too big to manage. Eventually this will lead to new systems, new degrees of accountability and most importantly, an integral part of their new culture.

Are Toyota’s Safe

Tuesday, March 2nd, 2010

A USA Today/Gallop poll recently asked the “Are Toyota’s Safe” question to Toyota owners and prospective buyers. Depending on how you look at the data, it’s either encouraging or discouraging.

Thirty-one percent of Americans now think Toyota and Lexus vehicles are not safe to ride, while 55 percent say the carmaker dragged its feet in responding to potential safety defects, according to a poll published on Tuesday. The USA Today/Gallup survey of 2,021 adults showed fewer doubts among current Toyota owners, with only 14 percent saying the cars are unsafe. A large majority of owners — 74 percent — say they have not lost confidence in the vehicles.

Pollsters said findings also suggest enduring loyalty to Toyota vehicles among prospective U.S. car buyers generally. While 17 percent of prospective buyers said they would no longer consider a Toyota vehicle, 53 percent said they would.

Interestingly, this closely aligns with what I projected on February 8th in the article Can You Trust Toyota? I made the following prediction.

The reason these “Can Toyota be trusted…” questions are important relates to Toyota’s future success or failure. As I read countless news articles relating to Toyota’s problems, it apparent that current Toyota customers fall into 3-categories.

  1. Faithful Toyota Followers: This group love their Toyota’s, and the many years of dependability, quality and service they have grown to love. This group likely comprises upwards of 50 - 60% of all current Toyota owners.
  2. Concerned Toyota Owners: This group loved their Toyota, but aren’t quite sure what to think now and they’re concerned. They’re asking the question, “Can Toyota be trusted…” This group likely comprises 20-30% of Toyota owners.
  3. Discouraged Toyota Owners: This group feels they’ve been betrayed. They’re reading the news reports and are concerned and possibly frightened. They don’t feel like Toyota has been true to the image they portrayed. This group comprises 10-20% of Toyota owners, and is growing.

The next couple of months is critically important for Toyota if they are to revive their brand and their business. It will not be an easy task, especially considering that new recalls are being announced (another 1.6 million autos will need to have leaky oil hoses fixed) and the potential for deepening recalls is possible (The NY Times recently completed an investigation suggesting that Camry’s prior  to 2007 might also be at risk of a recall). All of this is transpiring while worldwide auto sales is increasing and Toyota is suffering from a lapse in quality, transparency and safety.

Toyota’s silent problem (icebox variety) is now known. How the Toyota silent problem became visible is somewhat typical. The cost to the Toyota brand, cost of repairs, lost revenue from weak sales and fresh incentives to stimulate sales will likely top $50 Billion. And this is the real challenge that Toyota is facing. Its cash position is hemoraging quickly, which will make it more difficult to revive the brand and its quality position.

Silent Problems Being Revealed

Saturday, February 27th, 2010

 Do you wish the Toyota story would finally come to an end? Do you wish that Toyota would simply get back to the business of making great cars? Do wish that Toyota would simply come clean, take care of their problems, and move on? As much as I want to say “Yes” to each of these questions, the likelihood of it happening appears to be miniscule. The magnitude of Toyota’s problems is simply too great.

Over the past month, Toyota’s drive to fix its problems is being challenged at every intersection as new allegations, new lawsuits, and fresh dirty laundry come into the open. And from what I’ve seen, it appears that the tsunami has more destruction in its path.  Because the problems that Toyota has evidently been hiding for years are now beginning to surface, and will be fodder for front page news around the globe for the foreseeable future. And this is where Toyota’s quality and safety image is taking it on the chin.

In a Bloomberg story, Toyota Recall Crisis Said To Lie In Cost Cuts, Growth Ambitions, the authors investigate the “What went wrong” side of the story. And from the story, it’s apparent that cost cutting and corporate profits were Job 1, not quality or safety. For instance the article states, The company also had been too fixated on achieving a goal, set by Watanabe, of raising its operating margin to 10 percent to keep profit growing, the person described Toyoda as saying… At a 2006 investor conference in London Watanabe and former Executive Vice President Kazuo Okamoto discussed plans to “exceed the cost-reduction results achieved in CCC21” by eliminating vehicle parts and pushing suppliers to adopt lighter, cheaper materials. While the programs brought development advances, they may have inadvertently triggered quality glitches, said current and former company officials who asked not to be named because the information isn’t public.

Over at the Washington Post, Lawmaker accuses Toyota of withholding evidence reveals Toyota’s secretive “Book of Knowledge.”

Toyota withheld documents it was legally required to turn over in liability lawsuits the company faced and it paid higher settlements to plaintiffs to avoid revealing information contained in Toyota’s secret “Books of Knowledge,” a congressional committee chairman said Friday.

As I’ve been following and blogging about this story for over a month now, there appears to be several sides to the Toyota story now emerging.

  1. The Why Story: Why did Toyota pursue a path that was built on a deck of cards. Didn’t they realize it would eventually crumble?
  2. The How Story: How did Toyota go from being a company that was respected, to one that is being questioned and challenged? How did a company whose founding principles of quality and safety become a company of average quality and mediocre safety?
  3. The Where Story: Where were the corporate secrets held? This story is just now being told - i.e. The Book of Knowledge . Where did all of the quality and safety issues actually go  - were they simply throw into a big black hole?
  4. The What Story: What can we anticipate will surface in the future? What will Toyota attempt to do to diffuse the story and regain its fleeing customer base?
  5. The Money Story: How big will the final bill be once all of the lawsuits, recalls and reduced value of the company and future earning potential be? My guess - its much bigger than most are willing to fathom - $50 Billion?

 The cost of Toyota’s silent problems is immense. Toyota’s future is uncertain. The Toyota brand has been exposed. And unfortunately, Toyota has no one to blame but itself. They brought this on, and now owners of Toyota vehicles are suffering and Toyota’s employees exposed. I expect that next week will turn up some new information.

Safety, Quality & Transparency

Tuesday, February 23rd, 2010

Mr. Akio Toyoda, President of the Toyota Motor Company has been embroiled in controversy and fingerpointing for several months now. Today he sits in front of a U.S. Congressional hearing to defend his company and protect its future. As a prelim to this event, Mr. Toyoda had an Op-Ed piece published in the Wall Street Journal yesterday, titled Back to Basics for Toyota - it’s worth reading. If you’ve read my blog before and its numerous articles, its worth delving into Mr. Toyota’s position.

Mr. Toyoda’s Op-Ed piece is telling, because it gives us a peek into what he is thinking, and how Toyota will attempt to reinvent itself going forward. Therefore, I went through the article and did a simple word count for the words Safety, Quality and Transparency. This is what I found.

Safety: 10 times
Quality: 6 times
Transparency: 2 times

From this, it’s apparent that Safety is what is on the mind of Toyota’s customers and repairing the safety issue is “Job 1.” And the way to solving the safety issue (rebuilding trust) is through quality, which has historically been a core strength of Toyota. However the means to addressing the safety issue is by creating a culture of transparency. This is the feedback loop that enables Toyota’s engineers to design safer systems. Yet transparency is only listed twice. They are:

1st mention - 2nd paragraph: The first step is taking care of vehicles on the road today. But it also means making even safer vehicles in the future—and being more open and transparent about any safety issues that arise.

2nd mention - next to last paragraph: In short, I pledge that Toyota will set a new standard for transparency and speed of response on safety issues. 

This Op-Ed piece focuses on safety and quality, and only touches on the issue of transparency. Yet as recent reports have implicated, its the transparency issue that is at the heart of the Toyota Safety and Quality problem. And the lack of transparency is directly tied to the Japanese culture, which it doesn’t address. How will Mr. Toyoda create a culture of transparency? What does this mean? What systems will be put in place? Without a culture of transparency, it suggests that Toyota is ripe for silent problems (problems that are being avoided, neglected, go about unnoticed or are being intentionally silenced) into the future.

Bottom Line: Toyota needs to implement processes and procedures to deal with the silent problems inside the Toyota organization. It’s interesting, they have the system in place in their manufacturing plants today, and is core to their historical strength in quality and safety. Now they need to implement a similar process inside the management and leadership ranks at Toyota. And as I noted in my book, silent problems can be the most destructive problems of all. 

What do you think? Can Akio Toyoda do better?

 

Toyota’s Prime Time Movie Script

Wednesday, February 10th, 2010

As the Toyota Story unfolds, and new chapters are added on a daily basis, a central plot to the story continues to emerge. The plot includes elements of cover-up, deceipt and lack good judgement. Okay, really bad judgement. When one thinks about it, this story is filled with intrigue, surprises, money and of course, a world-class cast. And most importantly, the story has gone viral, and is spreading like wildfire. The publicity at times has overshadowed the Superbowl, and the upcoming Winter Olympics. It is a story with staying power!!!

It’s a story where the main character, Toyota Motor Company no longer lived its values, which made it strong in the beginning. It’s a story where silent problems (problems that are being avoided, neglected or going unnoticed) became embedded in the organization, and it became a slippery slope to disaster. It’s a story that will teach others many important lessons, at least to those that are watching.

Although the Toyota story isn’t a movie script, it could be. For instance today, an article over at the Huffington Post writes about Toyota’s Silent Problems, and how they kept them from being exposed. Here is an excerpt.

The recall of nearly 8 million Toyota vehicles was years in the making and was complicated by excuses offered to regulators and by delay tactics employed by Toyota, according to several news reports this morning.

Toyota’s relationship with industry regulators, as The New York Times, was a “kabuki dance” that even involved an unprecedented trip to Japan by National Highway Traffic Safety Administration Secretary Ray LaHood. Toyota execs were reportedly “dragging things out” and “offering excuses that didn’t make any sense.” puts it

Worse, the problems with the accelerators in Toyota vehicles were first spotted in 2003

As we look back at the Toyota story, one has to wonder why, which leads me to a favorite.

There’s a difference between truth and fiction. Fiction has to make sense.

And somehow, I think this states it all. Toyota has experienced a Humpty-Dumpty moment and only time will tell whether all of the pieces can be put back together.

Can You Trust Toyota?

Monday, February 8th, 2010

This is the question millions of Toyota owners and prospective owners are asking themselves today. And this is the question that will determine how quickly or if Toyota emerges from their current image, quality and PR problem in tact, or in taters. Here are just a few of the “Can Toyota be trusted” questions people are currently asking. 

  • Can Toyota be trusted to design and build a quality car? Probably yes.
  • Can Toyota be trusted to have their customer’s interest in mind once they have purchased a Toyota? Maybe.
  • Can Toyota be trust to divulge any other quality/safety issues they may be withholding? Don’t know.
  • Can Toyota be trusted to have customer safety as their No. 1 concern going forward? Too early to tell.
  • Can Toyota be trusted to resolve this current crisis, or is there more to come? That’s a big unknown.

The reason these “Can Toyota be trusted…” questions are important relates to Toyota’s future success or failure. As I read countless news articles relating to Toyota’s problems, it apparent that current Toyota customers fall into 3-categories.

  1. Faithful Toyota Followers: This group love their Toyota’s, and the many years of dependability, quality and service they have grown to love. This group likely comprises upwards of 50 - 60% of all current Toyota owners.
  2. Concerned Toyota Owners: This group loved their Toyota, but aren’t quite sure what to think now and they’re concerned. They’re asking the question, “Can Toyota be trusted…” This group likely comprises 20-30% of Toyota owners.
  3. Discouraged Toyota Owners: This group feels they’ve been betrayed. They’re reading the news reports and are concerned and possibly frightened. They don’t feel like Toyota has been true to the image they portrayed. This group comprises 10-20% of Toyota owners, and is growing.

Toyota’s “Can you be Trusted” challenge is the one question few market analyst’s are asking relative to Toyota’s future. It is the one question that only time will tell. At the very least, 10-20% of current Toyota owners are at risk. How  Toyota addresses “Can Toyota be trusted” customer concerns going forward is critically important in the outcome. At this point however, they have given numerous reasons why “Toyota can’t be trusted.” At the curret pace of events, Toyota could easily become another GM unless they change their ways.

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