2 Day Workshop

DATES: 29th & 30th  April, 2013

Day 1:  9.30am – 5.30pm / Day 2: 9am – 5pm

COST: Members €450 / Non Members €650 per person

LOCATION: Clonmel Park Hotel   www.clonmelparkhotel.com

Special Delegate Rate: €70 B&B single / €89 B&B double – Contact hotel directly & quote ICBE event Tel:052 6188700 reservations@clonmelparkhotel.com

Places are Limited / FULLY BOOKED

Customized training is also available - to find out more about bringing a trainer from Toyota Motors/ University of Kentucky to your organisation, contact Dermot at 061-423622 or dermot@icbe.ie

Each attendee/group to bring a problem that they can work on during the workshop


From Mass Production to Lean

  • Land Cruiser Round 1
  • History of Mass Production
  • History of Lean
  • Philosophy and Values of Lean – The Toyota Way
  • Lean Leadership

Introduction to Problem Solving & Step 1

  • Definition of a problem
  • ID the purpose of your work
  • ID the standard
  • ID the current situation
  • ID the gap between standard and current situation
  • Case Study & Exercise

Step 2 - Divide and Process

  • Divide up the problem
  • ID problem to process
  • ID the point of cause by processing the problem
  • ID the Problem to Tackle
  • Case Study & Exercise


Step 3 - Goal Setting

  • Make the commitment
  • Set specific, measurable, achievable, realistic and timely goal
  • Case Study & Exercise

Step 4 - ID Root Cause

  • ID potential causes
  • Go & See at the source and verify actual causes asking “Why?”
  • ID the root cause
  • Case Study and Exercise

Step 5 - ID Countermeasures

  • ID potential countermeasures
  • Narrow down the countermeasures to the most practical and effective
  • Communicate with others
  • Create an action plan
  • Case Study and Exercise

Steps 6, 7 and 8

  • Step 6 - Implement Countermeasures
  • Quickly and as a team, implement countermeasures
  • Report, Inform and Consult
  • Never give up, and proceed to the the next step quickly
  • Step 7 - Check process & results
  • Check process and results and communicate to all stakeholders
  • Evaluate from three key viewpoints: Customer’s, Company’s, and Yours
  • Understand and learn from failures and success
  • Step 8 - Standardize and Share Success
  • Standardize the effective countermeasure(s) to prevent reocurrence
  • Share your success with other affected areas
  • Plan on-going monitoring of the countermeasure
  • PDCA next improvement opportunity
  • Case Study and Exercise
  • Review and Summary
  • OJT Application Discussion

Center of Manufacturing, University of Kentucky www.mfg.uky.edu


Richard Alloo is a Toyota Motor Engineering & Manufacturing North America, Inc. (TEMA) Executive in Residence at the University of Kentucky, Center for Manufacturing.  In this position he is responsible for development of research relationships and projects for various new technologies with potential application to manufacturing processes and products.  He is a member of the University of Kentucky’s core group for developing multi-disciplinary research programs in sustainable manufacturing through the Center for Manufacturing.

Prior to his current assignment, Richard held the position of General Manager of the Production Engineering Planning Department at TEMA.  In this position, he was responsible for administrative, planning and advanced engineering functions for the Production Engineering Division.  These responsibilities included human resources planning and development, operational and capital budgeting as well as advanced manufacturing technology research and development for Toyota’s North American production preparation activities.

Richard started with Toyota in 1987 as Manager of Environmental Affairs during the construction and start-up of the Georgetown, Kentucky manufacturing facility.  He also performed various environmental consulting assignments for other Toyota manufacturing facilities throughout North America.  In 1992, he was assigned as acting Assistant General Manager for Facilities and Environmental engineering at Georgetown.

From 1993 through 1996 Richard held the position of Assistant General Manager for Production Engineering at the Georgetown facility.  In that position he was responsible for production process engineering support to Powertrain, Stamping, Body Welding, Painting, Plastics Molding, Final Assembly, Facilities and Environmental operations.

Richard held the position of General Manager of Vehicle Production Engineering at Toyota Motor Manufacturing North America from 1996 through 1999.  In this position he was responsible for production process preparation activities in Stamping, Body Welding, Painting, Plastics Molding and Final Assembly operations at Toyota’s vehicle manufacturing plants across North America.

Richard held the position of General Manager of Production Control at Toyota Motor Manufacturing Kentucky, Inc, from January, 2000 until August, 2003. In this position he was responsible for various functions including production planning, project management, environmental management, parts ordering, logistics and material handling.

Prior to joining Toyota, Richard held various engineering and environmental positions with General Motors Corporation in their vehicle assembly plants and central office.

Richard holds degrees in Electrical Engineering, from General Motors Institute, and Law, from Stanford University Law School.


We are pleased to be able to offer a limited number of free places for jobseekers on our network programmes subject to funding being available. Please click on the following link to check if you meet Jobseekers eligibility criteria

Skillnets funded from the National Training Fund through the Department of Education and Skills

ILSS is funded by member companies and the Training Networks Programme, an initiative of Skillnets funded from the National Training Fund through the Department of Education and Skills.

For more information on Skillnets, please visit www.skillnets.ie



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