Delphi began studying Toyota in 1996 to determine how to adopt its entire business model, said Dave Logozzo, director of manufacturing operations.
Delphi changed the job description for all of plant managers worldwide in 1998 to embrace Toyota Production System practices, he said.
Five of Delphi's factories won this year's Shingo Prize for Excellence in Manufacturing, an academic prize not affiliated with Toyota, but which awards manufacturers based on their success with the Toyota Production System.
'This is an ongoing effort,' Logozzo said. 'It isn't something you do and it's done. What we've accomplished is setting the direction. Every manager in our company now knows exactly where he is in the process.'