Page 141 - The Toyota Way Fieldbook

118 THE TOYOTA WAY FIELDBOOK

Secondary Lean
Strategies Primary Lean Tools
Tools
• Create a repeatable • Standardized work • Visual controls
work method that documents • Policies and
becomes the foundation • Standardized work procedures
for kaizen chart • Boundary
• Establish clearly defined • Production capacity samples
expectations sheet • Process check
• Develop processes to • Work Combination sheets
insure consistency for all Table • Job Instruction
elements of the work Training
• Labor needs
• Work Methods
• Materials
• Machinery

Table 6-1. Stategies and Tools for Standardized Processes and Procedures

Types of Standardization
There’s often confusion regarding the establishment of the process Toyota
broadly refers to as “standardized work.” This seemingly simple method is
deceivingly difficult for other companies to mimic. Since the intent of stan-
dardized work is different from the traditional process of creating work stan-
dards, it is not possible to make a direct correlation. Companies have methods
they call “standards,” but it’s not what Toyota means by using the term “stan-
dardized work” to define the method used to perform work tasks with the least
amount of waste. In fact there are many types of standards that are consolidat-
ed into one overriding method used to dictate the best work procedure. Within
Toyota, the primary tool that dictates the work method is standardized work,
which defines who, what, when, and where work is to be performed.
Figure 6-3 uses a house model to show the relationship of the different types
of standards and how they support the primary objectives of providing a
defined method to perform the work with the least waste, as well as to provide
detailed information to the employees about developing the highest knowledge
and skill level possible.
Notice that each standard serves a separate function, but they all must be
incorporated into the standardized work method. This does not mean that the
standardized work document includes all the standards. It simply includes the
work steps that will produce the desired result (achievement of other standards).
The details of other standards are included in operator instruction and training,
as can be seen in Figure 6-4.