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

118 THETOYOTAWAYFIELDBOOK

Types of Standardization

There’s often confusion regarding the establishment of the process Toyota
broadly refers to as “standardized work.” This seemingly simple method is
deceivingly difficult for other companies to mimic. Since the intent of stan-
dardized work is different from the traditional process of creating work stan-
dards, it is not possible to make a direct correlation. Companies have methods
they call “standards,” but it’s not what Toyota means by using the term “stan-
dardized work” to define the method used to perform work tasks with the least
amount of waste. In fact there are many types of standards that are consolidat-
ed into one overriding method used to dictate the best work procedure. Within
Toyota, the primary tool that dictates the work method is standardized work,
which defines who, what, when, and where work is to be performed.
Figure 6-3 uses a house model to show the relationship of the different types
of standards and how they support the primary objectives of providing a
defined method to perform the work with the least waste, as well as to provide
detailed information to the employees about developing the highest knowledge
and skill level possible.
Notice that each standard serves a separate function, but they all must be
incorporated into the standardized work method. This does not mean that the
standardized work document includes all the standards. It simply includes the
work steps that will produce the desired result (achievement of other standards).
The details of other standards are included in operator instruction and training,
as can be seen in Figure 6-4.

Strategies Primary Lean Tools Secondary Lean

Tools

• Create a repeatable
  work method that
  becomes the foundation
  for kaizen


• Establish clearly defined
  expectations


• Develop processes to
  insure consistency for all
  elements of the work
  
  
  • Labor needs
  
  
  • Work Methods
  
  
  • Materials
  
  
  • Machinery
    
    
    • Standardized work
      documents
      
      
      • Standardized work
        chart
      
      
      • Production capacity
        sheet
      
      
      • Work Combination
        Table
        
        
        • Visual controls
        
        
        • Policies and
          procedures
        
        
        • Boundary
          samples
        
        
        • Process check
          sheets
        
        
        • Job Instruction
          Training
        
        
        
        
      
      
      
      
    
    
    
    
  
  
  
  

Table 6-1. Stategies and Tools for Standardized Processes and Procedures