Page 193 - The Toyota Way Fieldbook

Chapter 7. Leveling: Be More Like the Tortoise Than the Hare 169

2. Establishing a “level schedule” requires up-front effort, and
diligence to sustain.
a. Evaluate the effect of the variation and decide whether
leveling the product flow would be beneficial.
b. Are you willing to make the effort to eliminate problems
that currently prevent you from producing smaller quanti-
ties more frequently and consistently?
3. If you’re producing a product to stock, establish a finished
goods supermarket to absorb the true customer variation.
a. Determine the average daily volume demand for your
products.
b. Determine a pitch time for each product. The highest 10 to
20 percent of products by volume (maybe more) should
be set for daily production.
c. Determine the repeating time pitch for the other products,
and create a “pattern” in which to produce the product.
Consider the mix of products required and the sequence
to produce them for balanced flow.
4. Your leveled schedule becomes a standard for operation.
Measure your effectiveness in achieving the standard and
correct obstacles that prevent consistent ability to achieve the
schedule. Note: Do not change the plan because the process
is not capable. Correct the weakness.
5. As a process continues to achieve higher levels of capability,
it is necessary to incrementally raise the bar. Evaluate your
value stream, and reflect on the following questions:
a. Do you know where the “point of control” is within your
value stream?
b. Are you measuring and managing the point of control?
c. What changes at the point of control will impact the entire
value stream?
d. How will these changes affect the value stream (where will
the chain break)?
e. Can you implement corrective action to the weakness in
the value stream prior to forcing the change?
6. Leveling is necessary to provide a “standard core” to which all
resources are aligned. Build these additional elements based
on your level schedule process:
a. Material replenishment: All material supply within the facil-
ity is based on the consistent requirement at each process.
This dictates the material replenishment pitch and is the