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

Time Team Members Team Leaders Group Leaders

Designated team members and team leaders

responsible for equipment start-up

Must arrive 30 minutes

prior to shift start

15-30

Min.

Prior to

Shift

Start

• Perform
  equipment start-
  up procedure


• Perform
  equipment
  condition checks


• Verify readiness
  of hand tools and
  work area


• Cycle machines
  for production
  readiness


• Perform first
  article inspection


• Verify material
  supply levels (raw
  materials)


• Report any
  problems or
  abnormal
  conditions


• Assure production
  readiness prior to
  shift start
  
  
  • Ensure the arrival of
    start-up team
    members
  
  
  • Review TL shift-to-
    shift logbook
  
  
  • Follow up on any
    issues from previous
    shift
  
  
  • Audit performance of
    start-up process
  
  
  • Respond to any
    problems with start-up
  
  
  • Verify condition of line
    from previous shift
  
  
  • Collect production
    instruction kanban
  
  
  • Verify daily production
    requirement
  
  
  • Determine changeover
    needs from kanban
  
  
  • Assure production
    readiness prior to shift
    start
    
    
    • Review daily attendance
      calendar
    
    
    • Receive calls for
      absences
    
    
    • Make adjustments to
      staffing
    
    
    • Notify assistant manager
      of attendance
    
    
    • Review G/L shift-to-shift
      logbook
    
    
    • Follow up on any issues
      from previous shift
    
    
    • Contact maintenance if
      necessary
    
    
    • Respond to any problems
      with start-up
    
    
    • Report potential
      production stoppages to
      assistant manager.
    
    
    • Implement production
      contingency plan if
      necessary
    
    
    • Audit performance of
      start-up process
    
    
    • Verify condition of line
      from previous shift
    
    
    • Be in work area 5 minutes
      prior to shift start
    
    
    • Verify start-up,
      attendance, no problems
    
    
    
    
  
  
  
  

Shift

Start

• Verify work
  placement for first
  period


• Report to assigned
  job location


• Be ready to work
  when the shift
  starts
  
  
  • Fill in for any absent
    TMs (Online TL)
  
  
  • (Offline TLs duties)
  
  
  • Assure smooth start of
    production
  
  
  • Assure that all TMs
    are punctual and in
    place
  
  
  • Assure TM
    compliance with safety
  
  
  • Assure TM
    compliance with
    standardized work
    
    
    • Verify sufficient TL
      coverage for production
    
    
    • Reassign offline TL as
      needed
    
    
    • Assume TL duties if
      necessary
    
    
    • Verify all TMs are in
      position on time
    
    
    • Record any unplanned
      absences or tardies
    
    
    
    
  
  
  
  

Table 10-1. Daily Activities of a Toyota Work Group