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

Less Is More: Reduce Waste by Controlling Overproduction

In a true one-piece flow, each operation only builds what the next operation

needs. If the next operation gets backed up for some reason, then preceding

Chapter 5. Create Connected Process Flow 83

Figure 5-1. Waste reduction model

Philosophy

Waste Elimination

Performance Measure

Reduced Lead Time

Principle

Create Continuous

Process Flow

Strategy

Create Interdependent

"Connected" Processes

Reason

Problems Are Surfaced

Quickly and Are Critical

Effect

Problems Must Be

Corrected Quickly

Result

Waste Is

Method Reduced!

Pull System

Lean Tools

Kanban, Supermarkets,

Defined FIFO Lanes

Control Method

Utilize Visual Controls So

That No Problems Are

Hidden

tools must be applied to provide the necessary structure to ensure success rather

than failure. The lean tools can help by providing both support systems and con-

trol methods to react appropriately to the problems that surface.