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

190 THETOYOTAWAYFIELDBOOK

Solution: Separate the dealer sheets by designated fax machine and

place the sheets in front of the machines so employees can trace the

line with a finger. The new layout is shown in Figure 8-9.

Implementing these changes reduced the errors significantly. It was

also discovered that errors were made in the initial programming of

codes. Even if the employee correctly identified the code, the fax was

sent incorrectly.

You may also ask, “Did you consider a verification process to

ensure that the fax was received by the dealer?” This was in fact

initiated, but bear in mind that this “solution” is similar to an inspec-

tion of product afterit has been produced. This extra step does not

address the root causes of the error, andit adds cost. It should only

be used for critical processes, and only after root causes have been

corrected.

The key to developing effective mistake proofing lies in understanding
how or why the mistake occurred. Do you understand the circumstances that
led to the error? Was this a random mistake or a repetitive one? Does the mis-
take happen with everyone or is there one person who has difficulty? If it is
an individual, the answer may be to evaluate standardized work and make
sure that no steps are omitted. If everyone has the problem, there may be a
singular cause such as missing information or a step that is not clear. Don’t
make the mistake of believing every error requires a “device” to prevent
recurrence.
The following case example demonstrates that there are always multiple
ways to solve any problem. Encourage your employees to be creative and to
seek solutions that are highly effective and low in cost. There is great power in
simplicity. Look around you to apply existing solutions from other problems to
your problem. The idea for Velcro was developed after an observation of “stick-
ers,” and the “problem” was converted to a solution to other situations.

Dealer List Fax

Machine #1

Dealer List Fax

Machine #2

Dealer List Fax

Machine #3

Dealer List Fax

Machine #4

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

Figure 8-9. Revised layout of dealer lists by fax machine