454 THETOYOTAWAYFIELDBOOK

Heijunka Audit Sheet

Auditors Date:

Shift:

Score:

# Question Yes No If no, please comment

{be specific}

(^1) Is card level in the box “on time”
(^2) Is box level loaded by volume?
(^3) Is box leveled by mix?
(^4) Heijunka box is in good condition /undamaged.
(^5) Is box free of debris and clutter?
(^6) Do all Finished Goods have PI cards attached?
(^7) Does all Bufferhave PI cards attached?
(^8) Does all Safety Stock have PI cards attached?
(^9) Have Buffer & Safety Stock been rotated?
(^10) Are all Finished Goods in correct location?
(^11) Are all cards and pockets in good condition?
(^12) Only PW cards are in Heijunka box.
At the work cells
(^13) Are reaction plans clearly posted at each cell?
(^14) Is reaction plan being followed if in red or
yellow condition?
(^15) Does packaging in flip-fold match PI cards?
(^16) PI card is attached to gondola in last 2 parts.
(^17) Are Safety Stock cards being built first?
At Stage-to-Ship area
(^18) PI Cards attached to sides near labels only?
(^19) Is FG quantity within target levels?
(^20) All totes in stage area have PI cards removed.

Additional comments or concerns: {if there is not enough room above}

Plot result on Heijunka Audit trend graph.
Figure 20-5. Heijunka audit