Alan Weir, recently retired from Toyota UK after nearly 34 years, delivered a moving keynote at Gemba Summit 2025 about what truly drives excellence in lean manufacturing. Speaking in Belfast where he grew up, Alan shared insights from his time as Deputy Managing Director at one of Toyota's most efficient plants globally. His message was clear: it's not about automation or technology - it's about people.

Through powerful video testimonials and real examples, Alan demonstrated how Toyota develops every team member into a problem solver through QC circles, how leaders spend their first two hours daily at the Gemba understanding real facts rather than reading reports, and how the Andon system empowers anyone to stop the line while being thanked for raising problems. He shared a detailed case study of reducing maintenance turnover through thoughtful leadership - spending one hour per week for two years listening directly to team members and relentlessly following up on their concerns. His concluding message captured Toyota's philosophy perfectly: "First we build people, then we build cars."

Key Takeaways:

• QC circles develop every team member into a problem solver, creating 2,500 problem solvers rather than relying on management alone
• Block out the first two hours daily for Gemba walks to understand real facts at the source, not through reports or presentations
• Every person has power to pull the Andon cord, and leaders thank them for raising problems - if the Andon isn't going off, that's the real problem
• Thoughtful leadership means not accepting surface complaints at face value, but creating focus groups and spending consistent time hearing directly from team members
• Take control of your diary and structure it around Gemba time, or other departments will fill every slot
• Toyota's competitive advantage isn't automation - it's the systematic development of people and future leaders

Speaker Details

• Name: Alan Weir
• Company: Retired, Toyota UK
• Website: www.toyotauk.com
• LinkedIn: www.linkedin.com/in/alan-weir-591a24a8/

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