JUNIOR EDITION for Ages 6+
Great Companies: From Lab to Billions · Book 2

Toyota: The Factory That Never Wastes

Why does the family car start every single morning, for years and years?

In this book, you will find out…

When you grow up, you could…

Who is in the story

SiriSiriLoves mysteries. Writes in a secret notebook.
HazelHazelEngineer. Keeps the river of cars flowing.
CharlieCharlieAsks one good question — then lets Siri find out.
WarrenWarrenTurns up late. Thinks about a hundred years from now.

Today’s mystery

Why does the family car start every single morning, for years and years?

Look for the clues. Try to guess the answer before Siri does!

Chapter 1

The Car in the Driveway

🔍 What is so special about an ordinary car?
At midnight, Grandpa Ben's old compass began to glow.
At midnight, Grandpa Ben's old compass began to glow.
It spun, and pointed straight out of the window.
It spun, and pointed straight out of the window.
SiriWait. Seriously?
It pointed at the family car. Cold. Quiet. Ordinary.
It pointed at the family car. Cold. Quiet. Ordinary.
SiriYOU are the next great company?
Every house on the street had a car. They started every morning. Nobody ever asked how.
Every house on the street had a car. They started every morning. Nobody ever asked how.
Grandpa's diary opened by itself:
Grandpa's diary opened by itself: "Find the river that builds cars."
Siri made a plan. Find the secret before the car drives her to school.
Siri made a plan. Find the secret before the car drives her to school.
SiriHere we GO!
Chapter 2

A River Made of Cars

🔍 Where does a car begin?
She landed above a river of car bodies, gliding slowly by.
She landed above a river of car bodies, gliding slowly by.
SiriIt's a RIVER made of cars!
An engineer caught a spinning bolt.
An engineer caught a spinning bolt.
HazelI'm Hazel. I keep this river flowing.
A bare steel shell moved past, then slowly became a shiny car.
A bare steel shell moved past, then slowly became a shiny car.
Hazel showed a map with seven stations.
Hazel showed a map with seven stations.
SiriI'll ride ONE car all the way through.
It starts as a giant roll of steel. As heavy as an elephant!
It starts as a giant roll of steel. As heavy as an elephant!
A huge press came down. BOOM! Out came a whole car door.
A huge press came down. BOOM! Out came a whole car door.
SiriIn ONE stomp?
Chapter 3

The Shape Is the Strength

🔍 How can thin metal be strong?
Siri folded a sheet of paper into a ridge. It stood up by itself.
Siri folded a sheet of paper into a ridge. It stood up by itself.
SiriThe bends make it strong!
Hazel nodded. Doors, floors and pillars, all full of curves, waited like a model kit.
Hazel nodded. Doors, floors and pillars, all full of curves, waited like a model kit.
🔎 Clue found!
A curve or a ridge makes thin metal strong.
Next came a storm of sparks. Robot arms danced around the car.
Next came a storm of sparks. Robot arms danced around the car.
SiriA robot ballet!
Each robot pinches two panels and zaps. A car has thousands of these dots.
Each robot pinches two panels and zaps. A car has thousands of these dots.
A person checked every seam too.
A person checked every seam too.
HazelRobots are steady. People spot surprises.
Hazel tapped the shell. It rang like a bell. Flat pieces were now one strong body.
Hazel tapped the shell. It rang like a bell. Flat pieces were now one strong body.
Chapter 4

The Part That Only Fits One Way

🔍 How do you stop mistakes?
The whole car sank into a glowing bath. Paint crept into every corner.
The whole car sank into a glowing bath. Paint crept into every corner.
SiriYou DIP the car?
Workers wore clean suits. One speck of dust could spoil the shine.
Workers wore clean suits. One speck of dust could spoil the shine.
Hazel handed Siri a part.
Hazel handed Siri a part.
HazelTry to fit it wrong.
SiriI can't! It only goes one way.
🔎 Clue found!
Make a part that can only fit the right way, and nobody can get it wrong.
At the next station, Hazel lifted a hood.
At the next station, Hazel lifted a hood.
HazelThe heart. It runs on tiny bangs.
Every part was made smoother than a mirror.
Every part was made smoother than a mirror.
SiriNo "close enough" here.
Then the body came down onto its engine and wheels.
Then the body came down onto its engine and wheels.
SiriThey call it the WEDDING!
The car rolled off by itself for the very first time.
The car rolled off by itself for the very first time.
Chapter 5

The Cord Anyone Can Pull

🔍 Who is allowed to stop the river?
At the last station, cars were sprayed with rain and shaken on rollers.
At the last station, cars were sprayed with rain and shaken on rollers.
A cord hung above the line.
A cord hung above the line.
HazelSee a problem? Pull it. Everything stops.
Siri thought about it.
Siri thought about it.
SiriBecause fixing it NOW is cheaper than later!
Hazel grinned. Siri had worked it out. People and machines stop the moment something is wrong.
Hazel grinned. Siri had worked it out. People and machines stop the moment something is wrong.
🔎 Clue found!
Stop and fix a mistake right away, and it never reaches a family.
Only a car that passed every test could roll out into the world.
Only a car that passed every test could roll out into the world.
But what feeds all seven stations?
But what feeds all seven stations?
SiriThere must be a giant warehouse!
Chapter 6

No Warehouse

🔍 Where are all the spare parts?
There wasn't one! Parts arrived hour by hour, just in time.
There wasn't one! Parts arrived hour by hour, just in time.
SiriAlmost NOTHING is stored?
An empty bin sends a card back. It says,
An empty bin sends a card back. It says, "One more, please."
Hazel listed her enemies. Waiting. Extra steps. Piles. Doing it twice.
Hazel listed her enemies. Waiting. Extra steps. Piles. Doing it twice.
HazelA pile hides problems.
Seats came from one town, glass from another. All met here on time.
Seats came from one town, glass from another. All met here on time.
A supplier smiled.
A supplier smiled.
SupplierWhen they get better, they teach us too.
Siri’s notebook
No piles. Each part arrives just when it's needed.
Siri saw the whole river at once.
Siri saw the whole river at once.
SiriIt's not a factory. It's an orchestra!
Chapter 7

The Car That Keeps Going

🔍 Why do people trust these cars?
In a yard stood very old cars. They still started on the first try.
In a yard stood very old cars. They still started on the first try.
SiriThey just keep GOING?
Hazel nodded. People don't want a surprise. They want it to start. Every morning.
Hazel nodded. People don't want a surprise. They want it to start. Every morning.
A grandpa handed his daughter the keys to her first car. The same badge he trusted.
A grandpa handed his daughter the keys to her first car. The same badge he trusted.
On a board hung thousands of notes. Every one was an idea from a worker.
On a board hung thousands of notes. Every one was an idea from a worker.
Hazel called it kaizen. A tiny bit better today. Again tomorrow. Forever.
Hazel called it kaizen. A tiny bit better today. Again tomorrow. Forever.
🔎 Clue found!
Thousands of tiny fixes, every day, make a car you can trust.
The compass pulled Siri to a gate with a name she knew.
The compass pulled Siri to a gate with a name she knew.
SiriTOYOTA! It's on our car!
Chapter 8

The Loom That Stopped Itself

🔍 How did it all begin?
Long ago, Sakichi built a weaving machine. It stopped itself when a thread broke.
Long ago, Sakichi built a weaving machine. It stopped itself when a thread broke.
SiriThat's the CORD idea!
His son Kiichiro sold the loom idea. He used the money to make cars.
His son Kiichiro sold the loom idea. He used the money to make cars.
After a war, the company was almost broke.
After a war, the company was almost broke.
With no money for big warehouses, an engineer named Ohno found a cleverer way.
With no money for big warehouses, an engineer named Ohno found a cleverer way.
His idea came from a supermarket. Shelves were filled only when a shopper took something.
His idea came from a supermarket. Shelves were filled only when a shopper took something.
SiriA shop taught a car factory!
An old friend of Grandpa's had one question.
An old friend of Grandpa's had one question.
CharlieWhat could break all this?
Siri looked at her red-string wall.
Siri looked at her red-string wall.
SiriIf people stop pulling the cord. Or stop fixing tiny things.
Warren had a question too.
Warren had a question too.
WarrenWill people still need cars in thirty years?
Siri thought of quiet electric cars.
Siri thought of quiet electric cars.
SiriMaybe a different heart. But they'll still need to get to school!
She woke in her own bed. The compass was quiet.
She woke in her own bed. The compass was quiet.
At breakfast she asked for a ride. Now she could see the whole river behind it.
At breakfast she asked for a ride. Now she could see the whole river behind it.
She wrote in her notebook.
She wrote in her notebook.
SiriBuilt with care. Stopped when wrong. Better every day.

All the clues

  1. A curve or a ridge makes thin metal strong.
  2. Make a part that can only fit the right way, and nobody can get it wrong.
  3. Stop and fix a mistake right away, and it never reaches a family.
  4. Thousands of tiny fixes, every day, make a car you can trust.

So… Why does the family car start every single morning, for years and years?

Every car is built with care, station by station. Anyone can stop the line to fix a mistake. Parts come just in time. And everybody makes it a tiny bit better every day.

OmahaIndia Junior · a simpler version of Book 1 for readers aged 6-8