Empowering Construction Leaders with World-Class Production Principles

Why This Masterclass is Critical for the Construction Sector

The construction industry faces a unique set of challenges: low productivity, skills shortages, quality issues, and spiralling costs. Traditional project management approaches often fall short of addressing these. This masterclass bridges that gap by adapting Toyota’s production thinking to the built environment.

Key Industry Challenges Addressed:

1. Low Productivity: Learn how to optimise workflows and balance resources using proven efficiency principles.
2. Quality Issues: Introduce structured approaches to embed quality into processes and achieve consistent, high-standard results.
3. Skills Shortages: Develop streamlined systems that minimise dependency on specialised skills, enabling more flexibility in operations.
4. Cost Overruns: Apply innovative approaches to reduce waste and streamline operations, effectively controlling project costs.

What is the Toyota Production System (TPS)?

The Toyota Production System (TPS) is a globally recognised approach to production management, focusing on eliminating waste, optimising flow, and ensuring quality at every stage. TPS has been credited with transforming Toyota into one of the most successful companies in the world.

Core Principles of TPS:

1. Jidoka: Building quality into the production process through automation with a human touch.
2. Kaizen: Continuous, incremental improvements driven by all team members.
3. Takt Time: Achieving a smooth production flow by balancing the rate of production with customer demand.
4. Heijunka: Production levelling to handle fluctuations in demand without overburdening resources.
5. Andon: Visual management systems to highlight abnormalities and ensure quick resolutions.

What to Expect from the Masterclass

The masterclass is structured around a guided tour, interactive workshops, and strategic discussions designed to provide practical insights and hands-on learning.

Programme Agenda:

• 08:30 – 08:45: Registration, Coffee, and Introductions
• 08:45 – 09:30: Introduction to TPS – Overview of Toyota Deeside and Fundamentals of TPS
• 09:30 – 10:15: Strategy Deployment and Key Tools (Takt Time, Standard Work, Andon)
• 10:15 – 10:30: Coffee Break
• 10:30 – 13:00: Guided Plant Tour – See TPS in action through a structured walkthrough of the plant, focusing on tools like Kaizen, Quality Control Circles, and Jidoka.
• 13:00 – 13:45: Lunch and Networking
• 13:45 – 14:15: Q&A Session with Toyota’s Lean Experts
• 14:15 – 15:00: Workshop – Moving from Construction to Production: Opportunities and Challenges
• 15:00 – 16:30: Breakout Sessions – Developing a Production Mindset for Construction Projects
• 16:30 – 17:00: Wrap-Up, Action Planning, and Next Steps

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Mark Worrall’s comments:
“We developed the Construction to Production Masterclass in collaboration with Toyota, and it has consistently proven to be both powerful and impactful for all attendees over the years we have been running it.

The hands-on approach, the clarity of the Toyota Production System (TPS), and the opportunity to “go, look, and see” the production facility and TPS in action have inspired participants to send more leaders from their organisations, including entire leadership teams and key suppliers, to develop their own ways of working.

Everyone—from clients and prime contractors to supply chain organisations—has gained valuable insights and ideas on how to transform their organisations and drive a shift towards production thinking in the sector.”

We are incredibly proud of our relationship with Toyota and the way we have combined the Toyota methodology with our expertise in construction to identify innovative ways to transform performance. For more information about this experience, please contact our team.

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