The disaster showed the vulnerability of extreme JIT. Toyota’s suppliers were concentrated in one region. Relying on PDF manuals alone couldn’t fix severed supply chains. Toyota evolved again: they mapped the entire supply chain (tier 1 to tier N), created shared risk databases, and developed a that is now a standard chapter in any modern TPS PDF.
The system evolved to include a "learning organization" feedback loop. Toyota created the Toyota Global Production Center to re-train managers globally. The PDFs from this era stress: "Genchi Genbutsu" (go and see for yourself). No more reports from a distant office. the evolution of a manufacturing system at toyota pdf
Ohno focused on identifying and removing "waste" in all forms—overproduction, waiting, and excess inventory. The disaster showed the vulnerability of extreme JIT