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

go through the first phase of the workday for group and team leaders, prior to
the shift.
The group leader (GL) is expected to arrive at work at least 30 minutes prior
to the start of production. The leader is expected to set an example in all areas,
but especially in promptness, attendance, and commitment to the success of the
team. By reviewing the large attendance calendar, which is posted and shows
all scheduled vacations, visible to the entire group, the GL is aware of any sched-
uled absences, and has established a plan for those on the previous day. Team
members are required to call in any unscheduled absences 30 minutes before
the shift. The GL then evaluates the staffing and determines what adjustments

228 THETOYOTAWAYFIELDBOOK

Time Team Members Team Leaders Group Leaders

Shift Start

to

Break Time

• Perform regular
  job duties


• Follow
  standardized
  work


• Collect data
  regarding
  production as
  required


• Perform
  changeovers
  as instructed


• Activate andon
  when problems
  occur
  
  
  • Respond to andon
    calls from TMs
  
  
  • Respond to any
    equipment
    stoppages
  
  
  • Report any
    problems to GL
  
  
  • Review production
    results every hour
  
  
  • Record results on
    tracking board
  
  
  • Perform quality
    audits every hour
  
  
  • Review scrap and
    rework
    containment area
  
  
  • Review production
    and material
    kanban status
  
  
  • Schedule any
    equipment
    changeovers
  
  
  • Respond to
    problems reported
    by customer
    process
  
  
  • Record any issues
    in TL shift-to-shift
    logbook
    
    
    • Respond to andon calls
      from TMs
    
    
    • Respond to any equipment
      stoppages
    
    
    • Report any major problems
      to assistant manager
    
    
    • Review production results
      every hour
    
    
    • Review scrap and rework
      containment area
    
    
    • Respond to problems
      reported by customer
      process
    
    
    • Walk through work area
      to review status of:
      TM safety compliance
      and unsafe conditions
      Quality of product
      Material/Process flow—
      Ensure that standardized
      work is being followed.
      Pay particular attention
      to shortages or excesses
      of production (these are
      indications of problems).
      Material inventory levels
      5S condition
      Hazardous waste
      storage and disposal
    
    
    
    
  
  
  
  

Table 10-1. (Continued)