A journey of a thousand miles begins with a single step.

"A journey of a thousand miles begins with a single step.”

Laozi

The wisdom of Laozi remains valuable in many ways. How do you interpret his teachings?

The original lesson of this phrase is as follows;

“Even if something is going to be a big problem, it is easier to deal with it early.”

This is a surprising but original lesson. It’s because the original phrase doesn’t say “single step.” Instead, it says “beneath the foot.” 【千里之行始于足下】 So, to solve a big problem like a thousand-mile journey, start with something right beneath your feet.

The usual way to interpret this phrase is as follows;

“When you have a large project, start with something nearby.”

There are various lessons from this phrase.

The first step is recognizing its importance. Too often, we spend too much time discussing the journey and procrastinating, rather than taking action. Starting is crucial.

It also suggests starting with something familiar or simple. Don’t begin with something unfamiliar. Look at where you are, and identify what can be done right now. By focusing on what we can do, we have more people taking action, and they can gradually take on new challenges.

Additionally, it highlights the importance of continuing to take steps and not stopping. Don’t stop. Keep moving forward. Even small progress is better than remaining still.

Both lessons pertain to the Toyota Production System journey.

A company launched a new product but faced high defect rates. They considered finding a new supplier or materials. While observing the factory, we noticed one team that produced no defects. We spoke to the team leader, who said, “I noticed the problem on the first trial. I didn’t see any specifications on the tooling. So I tested with other tooling and started using a different tool for this product.” The correct tooling was then provided to all lines, and the defects disappeared. We also implemented problem-solving measures during product development to address issues earlier.

A company faced rising demand and took two actions at separate plants. In one factory, they decided to introduce a new machine that showed promise of great results and was launched with much fanfare. However, the excitement was short-lived as the machine began producing many defects, which severely impacted the plant's costs. Experts on the machine were immediately called in from overseas, but the situation did not improve. Meanwhile, the other plant implemented Kaizen using the old technology. They focused on stability, reduced defects, and made the line more flexible. As a result, the old plant increased its output and eventually offset the losses from the new plant. After a year, management asked for the new machine to be evaluated similarly. The team leaders and maintenance crew examined one problem at a time, and ultimately, the defects damaging the business were completely resolved.

Laozi’s wisdom, "A journey of a thousand miles begins with a single step," remains relevant in today’s complex world.

By the way, what is the “single step” in the TPS journey? That is standardized work and Kaizen, including problem-solving. I know some people will claim that we need to separate the two, but that is a mistake. Standardized work and Kaizen are like the right and left legs. (Don’t ask which is right and which is left.) You need both to move forward. When you create standardized work, you'll see areas for improvement. Don’t separate Kaizen from testing ideas. After implementing Kaizen, ensure the standardized work is updated. Without updating the standardized work, it’s unclear how Kaizen has impacted your process. Or, maybe you just created new waiting or overproduction. Using the two as a step, we are on a long journey.

Take daily steps and enjoy the journey. "A journey of a thousand miles begins with a single step.”