Toyota Way Fieldbook : A Practical Guide for Implementing Toyota's 4Ps

DEFINE THE PROBLEM SITUATION Problem Summary Statement Units per hour is consistently below goal.• Condition is worsening.• O ...

340 THETOYOTAWAYFIELDBOOK Reflect and Learn from the Process Identify and select a problem you want to solve and use to reflect ...

TOYOTA’S CORPORATEslogan is “Yoi shina, yoi kangai,”which means, “Good thinking, good products.” This applies particularly well ...

causes of the problem beyond the most apparent. The following principles are a crucial part of the Toyota approach: The analysi ...

Chapter 15. Complete a Thorough Root Cause Analysis 343 TRAP In many cases we see people attempting to force the Five-Why proces ...

At this level the Five-Why chain has developed the first branch. Prior to ask- ing “Why?” for both branches, it’s important to u ...

therefore, they have a “high tendency” of occurrence. The cumulative effect of these small losses can be very great. In addition ...

346 THETOYOTAWAYFIELDBOOK Problem statement: The fabrication units per hour is below goal. Why? We are not able to make enough p ...

within the ability or responsibility of the person developing them. A critical thought process of the Toyota Way is the assumpti ...

“We like to work in a clean environment.” “Because the boss said we need to.” “It helps the quality of the product.” “It is part ...

Distill Root Cause Analysis to Simplest Terms Note that any problem has many possible causes, and therefore many root causes. At ...

As shown in the causal chain in Figure 15-2 above, the causes for produc- tion losses are time losses and scrap losses. This res ...

Chapter 15. Complete a Thorough Root Cause Analysis 351 Figure 15-9. Stack chart of work element times In addition to the time r ...

Putting It All Together: The A3 One-Page Report The analysis phase is typically where most of the problem-solving time is spent. ...

Figure 15-11. Completed analysis section of an A3 report ...

◆ Continually narrow to the most significant causes, and refocus the analysis accordingly. ◆ Determination of root causes should ...

Chapter 15. Complete a Thorough Root Cause Analysis 355 Avoid the temptation to identify solutions until you have identified an ...

JUST AS THERE AREmany potential causes and root causes for any problem, there isalwaysmore than one way to solve anyproblem! The ...

the only solution considered. The young engineer explains that the documentation supports the conclusion that this is a good sol ...

solutions. But first, ideas that won’t effectively work as countermeasures should be removed from consideration. During the brai ...