Abstract
A medical student applying for radiology residency was formerly employed by Toyota as an engineer. During that time, he learned that production-line employees found it difficult to install moonroofs, experiencing back pain after climbing into and out of trucks 120 times per day. He walked the production line and talked with team members, brainstorming process improvement ideas and developing a solution, which he reviewed and reflected on each day. Within months, his team rectified the ergonomic problems and designed and installed an in-line quality assessment device that improved workers’ experiences and saved the company over $8 million per year by reducing error rates.
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