Knowledge-Based Assessment Applied to Lean Brazilian Toyota Plants

Abstract

This paper proposes knowledge-based assessment applied to Brazilian Toyota plants which practice Lean manufacturing to evaluate work, production, and knowledge factors based on the perspective of blue-collar workers and managers. The two researched plants were selected based on being pure Toyota DNA representatives, and belong to two Toyota auto parts makers (‘polar' cases), in which TPS is “transparently observable.” The results evidence that employees judge factors related to people as important and considered the relationship between knowledge and Lean in the plants are aligned. The data indicates that the Brazilian culture does not influence changes in the Toyota work context and DNA. The contribution of this study is to provide an assessment instrument that integrates the production, knowledge, and work context for a Lean system, understanding blue-collar manufacturing employees and front-line supervisors are therefore essential to the success of a Lean implementation. Finally, the paper offers a guideline to assess and develop a favorable context to encourage knowledge sharing.