Applying Toyota-style problem solving to personal and professional challenges (webinar)
In this engaging webinar, Jess Orr, a continuous improvement practitioner with roots at Toyota and founder of Yokoten Learning, explains how A3 thinking is far more than a Lean tool used at work.
It is a disciplined way of thinking that can be applied to everyday life.
Jess shares how A3 helps people slow down, resist the urge to jump to solutions, and instead deeply understand problems before experimenting toward effective, sustainable improvement.
What makes this session memorable is that she doesn’t use a manufacturing example.
She uses herself.
The Personal Case Study
Jess realized she was having repeated communication breakdowns. Conversations were being misunderstood. People were walking away with the wrong message. It was affecting her work and relationships.
So she did what Lean practitioners rarely do.
She pulled out an A3 and used it on herself.
She defined the problem, measured her current condition, used 5 Whys to uncover root causes, experimented with countermeasures, and tracked the results over time.
The result was significant improvement—not perfection, but measurable progress.
What A3 Thinking Really Is
Jess emphasizes that A3 is not a template to fill out after you already know the answer.
It is a structured thinking process built on the scientific method:
- Define the problem clearly
- Understand the current and target conditions
- Identify true root causes
- Experiment with countermeasures through PDCA cycles
- Measure results
- Sustain gains
- Reflect and learn
The A3 document is simply a visual record of that thinking.
Where A3 Fits Among Other Methods
Jess explains when A3 is appropriate and when it isn’t.
Simple “just do it” problems don’t need an A3.
Highly complex analytical problems may need Six Sigma or other tools.
Most real-world problems fall in the middle—where A3 thinking shines.
The Power of Root Cause and Team Input
A key lesson is the importance of not jumping to solutions.
Jess demonstrates how she used 5 Whys to uncover that her issue wasn’t “communication skill” but things like:
- Jumping to conclusions
- Failing to update mental models with new information
- Stress overriding rational thinking
She also shows how involving others in the process revealed blind spots she couldn’t see herself.
Experimentation, Not Perfection
Rather than trying to “fix” everything at once, Jess ran small PDCA experiments with specific countermeasures, such as:
- Using the Socratic method to better understand conversations
- Creating time between stimulus and response when stressed
- Seeking structured feedback after key conversations
She measured improvement with both a communication assessment and real-world feedback.
Sustaining Gains and Reflection
Jess stresses that many A3 efforts fail because teams skip the sustain phase.
She created a simple control plan with regular check-ins and measurable triggers to revisit her countermeasures.
She also reflects on what she would do differently next time—demonstrating that A3 thinking itself is a continuous improvement process.
Key Takeaway
A3 is not about paperwork.
It is about disciplined thinking.
When used properly, it helps people slow down, see clearly, learn from failure, and make meaningful progress—not just at work, but in everyday life.
Jess Orr
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