Toyota Way Fieldbook : A Practical Guide for Implementing Toyota's 4Ps
flow is attempted prior to achieving stability, the impediments may be too large and the creation of smooth, consistent flow wil ...
As we noted earlier, it is not our intent for this to be a “how to implementlean tools” book. There are already numerous books f ...
by Taiichi Ohno to train new members. This is part of the philosophy of genchi genbutsu, which emphasizes going to the actual pl ...
the most powerful uses of standardized work is for analyzing and understanding waste in the operation. The documented work proce ...
at it and ask, “What does it look like?” Perhaps the answers will be, “Messy, lots of moving around, lots of crisscrossing, back ...
flow. As you can see, the walking time is two-thirds as long as the work time, and the picture shows a nonlinear work pattern wi ...
Consolidate Waste Activities to Capture Benefits This strategy is often overlooked because of misguided beliefs. One such belief ...
66 THETOYOTAWAYFIELDBOOK Case Example: Consolidate and Conquer the Waste In this example several operations were working indepen ...
Chapter 4. Create Initial Process Stability 67 In addition to establishing an available resource, the consolidation of non-value ...
Another misguided belief is that it’s preferable to perform certain activities less frequently so that waste is minimized. This ...
on the assembly line is 30 feet long. The reason for the length is a combination of the variety of parts the operator is respons ...
and only one item (part) because the material is delivered in large heavy containers requiring a forklift. There is substantial ...
empty containers that are collected by the material handler. The rack is also deep enough to hold several containers of each par ...
dramatically reduce this time. Also known as “quick changeover,” or “rapid changeover,” this method can be applied any time equi ...
lost time opportunity by shifting from the non-value-added to the value-added side. From the non-value-added list we first focus ...
to “external” (performed while the saw continues to add value) was borrowed from the quick changeover technique. These changes w ...
A common example of external variability is product demand, or model mix. The reality in today’s manufacturing environment is a ...
Case Example: Isolating Variability in a Low Volume Aerospace Supplier This company produced welded tube sections for the aircra ...
and on the high end, tubes required 30 minutes to several hours to complete (some could take days). From this perspective, the l ...
a foundation for creating flow and establishing standardization. In essence, this isolation of variation is a basic application ...
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