-the Toyota production system "lean" as a total system including design does have massive flaws; i have known that for years and you are quite right it was only a matter of time before it caught Toyota up; i have said for years Toyota will start having issues and they will (with doubt); Toyota are going to implode as BM will and is undergoing massive change and BM will have issues (I think BM will merge with someone)
-the book "the machine that changed the world" is a very good book and from your comments I am not sure you have read it all; its a fantastic book and as dar as I know the teachings of hte book were ones of action and comparison and differentials; what is done differently, how do you get better; if you read the book in context of the market and look at what its actually saying; take the book in sections.
-Toyota and Japan are going through massive cultural changes, you start getting all sorts of things, go have a look at "Hoshin Kanri"; Japan and Toyota are going through massive changes and the bigger the organisation the more the effect; its going to be really interesting the next five to six years re. Toyota.
-you got to think now that the book MCW must be what 20 years old (it must be at least 15) and it shows just what a massive set of advancements other manufacturers have made and some assumptions etc; if you look at the context of the book and plug it into todays market; but this would take a long time to explain.
-the chevy spark is only a very small city car and four stars does not mean it would not get five stars in crash tests as I think now the Encap people are placing in pedestrian safety where it might not have scored well; i think the smart car only got 3 stars, Subaru Impreza got 4 stars and the c1 got 4 stars; also they may retest the spark to get it higher
-you will also notice the Cruze got 5 stars