Lean Strategy · Coaching · Toyota Management Practice

Guiding organisations
on their Lean journeys.

We build productivity and quality through lean business strategies shaped to each organisation’s unique situation — underpinned by an unparalleled depth of experience in Toyota Management Practices, and a human-centred coaching capability that resonates at every level.

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Gemba 現場: “The place where value is added and the truth revealed.”
Guides: “To light the paths of your Lean journey.”

01 — About

From the birthplace of Lean to your Gemba.

Researchers Womack, Jones and Roos coined the term “Lean” to describe Toyota’s revolutionary management processes in their 1990 book The Machine that Changed the World. Since then, Lean has become the dominant signature of a movement based on Toyota practices — now applied wherever customer value is created: in manufacturing, resources, healthcare, financial services, government, retail, hospitality and more.

We understand that being a “believer” is fundamental — but the pathway to operationalise the thinking and turn it into a self-sustaining culture is more difficult.

Our philosophy is to use our experience to help organisations deliver benefits to all stakeholders — benefits that flow through to the broader community and society. How we work with organisations matters most to us, and differentiates us from others: proven techniques to engage the front line to unlock value and improve performance, and to align the real work and its improvement to the organisation’s true-north objectives.

The Lean Journey — Plan, Do, Check, Action cycle with Gemba Guides services: Strategy, Coaching, Tools, People

Industries we’ve guided

Automotive Retail, Service & Repair
Building & Construction
Manufacturing
Mining & Processing
Warehousing & Logistics
Healthcare
Clothing & Textiles

Our developmental roots are in automotive at Toyota — the pioneer and ongoing benchmark for Lean management thinking — and we have applied Lean across this full range of industries.

Vision & Mission

Strong, sustainable organisations — for all stakeholders and society.

Our mission: guiding organisations in the practical application of true lean thinking.

To respect each organisation’s people, history and aspirations.
To see each Gemba through “fresh eyes”.
To transfer our skills efficiently.
To see sustainability as our contribution.
To give back, through special support to SMEs and not-for-profits.

02 — Primary services

Four ways we guide.

Strategy

Lean strategy is our core strength. With a depth of strategy experience gained from working inside Toyota and with a range of external companies, Doug can diagnose the current situation and assist in developing strategies and tactics to overcome the most difficult problems in getting a lean journey on track — drawing on deep experience in change management, organisational development and leadership. This is where many lean initiatives struggle. Strategy guidance can range from working with a Board, a CEO, senior operational management or an internal lean promotion manager.

Coaching

Ultimately, lean is about developing and empowering people at all levels. Many can teach the theory — what is usually lacking is the experienced, skilful coach or mentor supporting the people who need to lead change. Such a coach can dramatically build the capability and confidence of leaders: as a sounding board, in the background giving feedback, or teaming up to tackle tough situations. Coaching can be very effective and economical, with a minimal time commitment. Continuity is the key.

Tools

Lean has many tools and systems, but they must be appropriately applied to the circumstances and stage of a lean journey. In conjunction with an overall strategy, we advise on the few tools that make up a minimum system of work — which, when PDCA is applied consistently, can “pull” in the other tools and practices in a sustainable, developmental way, matching the learning agility of the organisation. Using pilot areas — going narrow and deep — the organisation identifies barriers and systemic problems to solve before wider deployment. This is the efficient, cost-effective pathway.

People

Developing people by engaging them in the lean journey is crucial. Existing people are the best — but where necessary, we support recruitment and training to develop the right people to match the culture, with the skills and aptitudes to grow with the organisation’s lean journey. We support diagnosis and assessment, change-management strategies, leadership development, and vision and objective setting to align the lean journey to business goals.

03 — Your guide

Doug Rickarby, Managing Director and Principal Guide of Gemba Guides — **Doug Rickarby** Managing Director & Principal Guide

One of the first people outside Japan to be deeply ingrained in Toyota fundamentals — over 35 years ago.

Doug, a manufacturing engineer by training, spent his career applying Toyota fundamentals to the many situations and circumstances of Toyota Australia, its suppliers and business partners. He initiated Toyota’s Supplier Development program in the late 1980s, and has since continued to adapt those same lean principles to the Australian context in Toyota and non-Toyota companies.

Doug later gained extensive experience in human resources, leading Toyota Australia’s Training & Development function through periods of extensive restructuring and consolidation. He subsequently held senior management roles in Purchasing, Supply Chain Management, Corporate Strategy & Planning and Manufacturing operations.

In the final phase of his Toyota career, as Divisional Manager of Manufacturing, Doug led his 2,000-plus manufacturing employees through their transition programs while achieving “Last car = Best Global Car” plant performance levels until the final cessation of operations in October 2017.

35+ yrsToyota management practice
2,000+people led through transition
Board → floorworks at every level

04 — Collaborators

Aligned, independent, versatile.

Closely aligned independent collaborating organisations give us the versatility, flexibility and options to support the integrated strategies and holistic approach any journey can require.

Alignments Australia

David Finn is a leadership and management training specialist with vast experience across corporate Australia, who understands what’s required in leaders to build culture and deliver performance. David works with teams and individuals at all levels, from frontline to executive.

Action Lean Ops

Christian Zimmer is an astute, highly experienced engineering and maintenance manager who has led the reformation of work systems and cultures — breaking down traditional demarcation while building people’s engagement in ownership and continuous improvement. He can support a lean journey on many levels, including specialist and accredited training support services.

Pro bono & special-rate support

We set aside time to give back.

We have been fortunate to be supported in developing our skills over many years, mainly in the automotive industry. We provide pro-bono or non-commercial rates for not-for-profits and small Australian companies with unique or strategic potential to benefit the local community through employment growth or export potential.

Talk to us about what we can offer →

The Gemba Guides network of experienced lean practitioners

Guiding organisationson their Lean journeys.