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

at it and ask, “What does it look like?” Perhaps the answers will be, “Messy, lots
of moving around, lots of crisscrossing, backtracking, etc.” Visually, people will
see that the work flow is not good. If you are fortunate to have good work flow
at this stage and do not see a messy picture, you’re ready to go a level deeper
and analyze for smaller hand motions.
Figure 4-1 shows a completed waste analysis, including the work steps, the
work and walking time (in seconds), and the pictorial view of the operator work

Chapter 4. Create Initial Process Stability 63

Figure 4-1. Completed waste analysis

Work Step Work Time Walk Time

1. Pick up A Bracket 1


2. Load Fixture (walk to fixture) 2

2

2

3

3

3

3

1

1

3. Pick up B Bracket 1


4. Load Fixture 5


5. Pick up Side Support 1


6. Load Fixture 3


7. Pick up Stiffener 1


8. Load Fixture 8


9. Pick up Brace 1


10. Load Fixture (start over) 5
    32 22

Fixture

1

2

A

Bracket

3

4

5

6

Side

Support

B

Brace Stiffener Bracket

9

10

7 8

Excessive walking time!

Backtracking and criss-

crossing walk paths

6

Total Seconds

2