Page 166 - The Toyota Way Fieldbook

Chapter 6. Establish Standardized Processes and Procedures 143

d. Inability to consistently achieve the takt rate is an indicator
of instability. Identify the causes and necessary corrections
to reduce instability and to achieve the standard (takt rate)
at least 85 percent of the time.
2. Defined, dedicated, and controlled connections between
processes serve as agreed-upon expectations of performance
(standards) between a supplier process and a customer pro-
cess. Review your connections and answer these questions.
a. Is there visual awareness of the standards?
i. What is the expectation?
ii. When is it supposed to be done?
iii. Who is supposed to do it?
iv. How do you know if it has been successfully com-
pleted?
b. What is the current ability to achieve the standard (satisfy
the customer)? If the performance is below 85 percent, iden-
tify necessary steps to improve performance, and make a
plan to implement it.
3. Identify an operation that does not consistently achieve the
standard. Stand in the circle, and observe the following con-
ditions.
a. Is the work method repeatable? (If it’s difficult to docu-
ment the work steps because of constant interruption, it
is not repeatable.) If not, list the causes of variation and
corrective actions necessary to stabilize the process.
b. Is the work process interrupted more than 10 percent of
the time because of equipment issues or quality-related
problems? (Don’t overlook small issues such as difficulty
loading or unloading a fixture.) Make plans to correct the
issues that interrupt the process.
4. After the major issues have been resolved and the process is
reliable and stable, stand in the circle to study the job and
identify waste.
a. Use a Standardized Work Sheet to document the steps of
the job.
b. Draw a diagram of the work area and where each step is
performed.
c. Note the waste, and develop plans to improve the work
process to reduce the waste.