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

Chapter 8. Build a Culture That Stops to Fix Problems 189

To simplify this task to minimize errors, let’s look at the potential causes

of errors.

Error: Incorrect matching of dealer with fax machine and code.

Why does this error occur?

1. The two pieces of information used are at opposite ends of the long

sheet (almost 20 inches apart).

2. There’s no visual delineation between lines on the sheet, making it

easy to cross into the next line.

3. The sheets are behind the machine, where the employee can’t use

a finger to trace across the line.

Solution: Reformat the sheet so the dealer name and the code are side

by side. This minimizes the possibility of crossing lines. Also, shade

every other line so it’s easier to stay within the correct line, as shown in

Figure 8-7.

Dealer Name Pre-Programmed Code Dealer Region Dealer Address Dealer Representative Phone Number Fax Number

A Plus Cabinets Fax Machine 2- #49 South West

111 Short Street

Anytown, AK John Smith 888-555-1212 888-555-1213

Astounding Cabinets Fax Machine 2- #32 East

555 West Main,

Yourtown, MS George Jones 877-222-2222 877-222-1234

Figure 8-7. Reformatted dealer list

Dealer List Dealer List Dealer List Dealer List

Fax Machine #1 Fax Machine #2 Fax Machine #3 Fax Machine #4

Figure 8-8. Arrangement of dealer lists by fax machine

Error: Employee does not use the correct fax machine identified.

Why does this error occur?

The sheets are spread out behind the fax machines and the employee

has to remember the correct machine identified and locate the correct

machine. Figure 8-8 shows this condition.