Earlier this year, at 5 different locations, 5 CEOs made almost the same public appearance apologizing to the public for data falsification. The 5 companies, Toyota, Honda, Mazda, Yamaha & Suzuki, were discovered in falsifying vehicle safety testing data including pedestrian safety test, collision test & noise level measuring test.
4 crucial missteps that rumble the golden pedestal of Japanese manufacturing
“We deeply regret and apologize on the incident.” Said Akio Toyoda, Chairman of Toyota Motor Corporation.
The recent revelations of data falsification by Japanese manufacturers have raised serious concerns about the integrity of their quality control processes and the potential impact on consumer trust. This incident serves as a stark reminder of the importance of transparency, accountability, and robust quality assurance measures in the manufacturing industry.
As we delve into the lessons learned and explore ways to prevent such occurrences in the future, it is crucial to understand the underlying factors that led to this breach of trust and to implement comprehensive solutions that can restore confidence in Japanese manufacturing.
“This incident can be understood as a technical allowance, such as slightly modifying numbers within the acceptable range, which would not affect engine performance. The production line made a judgment based on this explanation, and we lacked oversight of this judgment.” Toshihiro Mibe, CEO of Honda Motor Co.
One of the key lessons from this incident is the need for a strong corporate culture that prioritizes ethical behavior and quality over short-term profits. The pressure to meet ambitious production targets and maintain a flawless reputation can sometimes tempt companies to take shortcuts or manipulate data, as was the case with these Japanese manufacturers.
Additionally, the implementation of robust and independent quality assurance systems is essential. This may involve the integration of advanced technologies, such as data analytics and automated inspection processes, to enhance the reliability and transparency of quality control measures. Furthermore, the establishment of third-party auditing and certification programs can provide an additional layer of scrutiny and accountability, ensuring that manufacturers adhere to the highest standards of quality and integrity.
“Some of the standard operating procedures and protocols were insufficient, leading the frontline staff to develop their own interpretations. This resulted in methods that did not comply with regulations, causing the current outcome.” Masahiro Moro, CEO & President of Mazda Motor Co.
Data from a Manufacturing Execution System (MES) is critical but often just the starting point for managing the production process and ensuring future quality. MES systems gather data at specific intervals, but they can miss the finer details and real-time anomalies that impact quality. These systems are often isolated, lacking integration with ERP, SCM, or PLM systems, which limits comprehensive data analysis.
These integrations provide the granularity, real-time monitoring, advanced analytics, and regulatory compliance needed to optimize production and ensure quality. MES data is an essential feature, but it’s just one piece of the puzzle in mastering production management and quality assurance. It’s like Steve Jobs said about Dropbox: a tremendously useful feature, but a feature nonetheless. To truly get the full picture, you need a holistic, integrated approach.