Page 106 - The Toyota Way Fieldbook

Chapter 5. Create Connected Process Flow 83

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.

Philosophy
Waste Elimination

Principle
Performance Measure
Create Continuous
Reduced Lead Time
Process Flow

Strategy
Create Interdependent
"Connected" Processes
Result
Waste Is
Lean Tools
Method Reduced!
Kanban, Supermarkets,
Pull System
Defined FIFO Lanes

Reason
Problems Are Surfaced
Quickly and Are Critical

Control Method Effect
Utilize Visual Controls So Problems Must Be
That No Problems Are Corrected Quickly
Hidden

Figure 5-1. Waste reduction model

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