Page 213 - The Toyota Way Fieldbook

Chapter 8. Build a Culture That Stops to Fix Problems 189

To simplify this task to minimize errors, let’s look at the potential causes
of errors.

Error: Incorrect matching of dealer with fax machine and code.
Why does this error occur?
1. The two pieces of information used are at opposite ends of the long
sheet (almost 20 inches apart).
2. There’s no visual delineation between lines on the sheet, making it
easy to cross into the next line.
3. The sheets are behind the machine, where the employee can’t use
a finger to trace across the line.

Solution: Reformat the sheet so the dealer name and the code are side
by side. This minimizes the possibility of crossing lines. Also, shade
every other line so it’s easier to stay within the correct line, as shown in
Figure 8-7.

Dealer Name Pre-Programmed Code Dealer Region Dealer Address Dealer Representative Phone Number Fax Number
111 Short Street
A Plus Cabinets Fax Machine 2- #49 South West Anytown, AK John Smith 888-555-1212 888-555-1213
555 West Main,
Astounding Cabinets Fax Machine 2- #32 East Yourtown, MS George Jones 877-222-2222 877-222-1234
Figure 8-7. Reformatted dealer list

Error: Employee does not use the correct fax machine identified.
Why does this error occur?
The sheets are spread out behind the fax machines and the employee
has to remember the correct machine identified and locate the correct
machine. Figure 8-8 shows this condition.

Dealer List Dealer List Dealer List Dealer List

Fax Machine #1 Fax Machine #2 Fax Machine #3 Fax Machine #4

Figure 8-8. Arrangement of dealer lists by fax machine