Page 140 - The Toyota Way Fieldbook

Chapter 6. Establish Standardized Processes and Procedures 117

waste, we must reduce or eliminate variation within processes. Variation is the
antithesis of standardization. By definition, variation implies the inability to
standardize. As discussed in Chapters 4 and 5, the isolation of variation is a key
to the establishment of standardized work methods and procedures. This will
also establish a baseline and the ability to distinguish the (normal) standard
method from (abnormal) nonstandard methods. Visual control methods and
other lean tools are utilized to provide instant recognition of performance, and
adjustments can be made in real time so performance objectives are achieved
consistently.

Strategies to Establish Standardized
Processes and Procedures

The primary tools in establishing standardized processes and procedures are
standardized work documents and many of the lean tools that were used during
the previous phases are also used in the development of workplace standards
(Table 6-1).
Traditional policies and procedures often work against standardization.
Consider attendance policies. With standardized work processes it’s manda-
tory that every work position be filled at all times. This means that when a
person is absent, he or she must be replaced in order for the process to func-
tion correctly. It can’t function correctly when there are no contingencies as to
how the position will be filled in the event of absence. Yet, in traditional sys-
tems absenteeism is rarely a top management focus and supervisors scram-
ble around to fill positions due to absences each day without a standardized
approach.

TIP
Create a Structure to Support Standardized Work
Toyota has a system of group leaders and team leaders. The team
leaders are hourly and are responsible for supporting about five
to seven associates. They audit the work procedures of employees
to detect deviations from standard work (see Chapter 11 here and
page 191 of The Toyota Way) and provide the necessary structure
to fill in for absences. They are often involved in developing stan-
dard work for new models. They are a key to turning standard
work from good looking wall hangings to true tools for continuous
improvement. Interestingly, the team leader role is exactly what
is missing in most companies.