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

Chapter 18. Telling the Story Using an A3 Report 385

Date: 6/9/2004 Prepared by: David Meier

REPORT FORM

Week 1 Week 2 Week 3 Week 4

Temporary cleaning during breaks and lunch ST M. Scarpello

Tape boxes to machine to collect dirt ST D. Danis

Reduce walk time: relocate material and inspection LT D. Spiess

Reposition start button LT M. Kissel

Build skirt around tables to reduce cleaning LT M. Nicholson

Add dust collection bin to machine LT P. Kenrick

Modify 4 machines to catch dirt (1per week) LT B. Costantino

Key: Start Finish Progress Check

Action Item Short-TermLong-Term ResponsiblePerson Schedule

2004—Weekly Units per Hour

Fabrication Line

30

32

34

36

38

40

26-Feb4-Mar11-Mar18-Mar25-Mar1-Apr8-Apr15-Apr

Units per Hour

Goal = 36

2004—Overtime $ per Month

0

20

40

60

80

100

JanFebMarApr

$ 000's

2004—Monthly Late Shipments

0

10

20

30

40

50

60

70

JanFebMarApr

Quantity

Summary of Results

• Reduced walking by 5 sec/cycle = 7 Units/Hr.


• Reduced cleaning 15 minutes/shift = 2.5 Units/Hr.


• Units per hour are consistently above goal.


• Process is stable.


• Overtime costs decreasing.


• Number of late shipments decreasing.


• Floor space reduced.


• Continue improving dirt containment and control activities.


• Develop automatic unloading device to further reduce cycle time.


• Improve handling to further reduce cycle time.


• Begin activity to correct other causes of late shipments.

4. RESULTS OF ACTIVITY


5. FUTURE STEPS


6. ACTION PLANS TO CORRECT PROBLEMS

Figure 18-5. (Continued)