Page 412 - The Toyota Way Fieldbook

Chapter 18. Telling the Story Using an A3 Report 385

REPORT FORM
Date: 6/9/2004 Prepared by: David Meier
3. ACTION PLANS TO CORRECT PROBLEMS
Short-Term Person Schedule
Action Item
Long-Term Responsible Week 1 Week 2 Week 3 Week 4
Temporary cleaning during breaks and lunch ST M. Scarpello
Tape boxes to machine to collect dirt ST D. Danis
Reduce walk time: relocate material and inspection LT D. Spiess
Reposition start button LT M. Kissel
Build skirt around tables to reduce cleaning LT M. Nicholson
Add dust collection bin to machine LT P. Kenrick
Modify 4 machines to catch dirt (1per week) LT B. Costantino
Key: Start Finish Progress Check
4. RESULTS OF ACTIVITY
2004—Weekly Units per Hour 2004—Overtime $ per Month
Fabrication Line 100
40
Units per Hour 38 Goal = 36 $ 000's 60
80
36
40
34
20
32
30 0 Jan Feb Mar Apr
26-Feb 4-Mar 11-Mar 18-Mar 25-Mar 1-Apr 8-Apr 15-Apr
2004—Monthly Late Shipments
70
Summary of Results 60
• Reduced walking by 5 sec/cycle = 7 Units/Hr. 50
40
• Reduced cleaning 15 minutes/shift = 2.5 Units/Hr. Quantity 30
• Units per hour are consistently above goal. 20
10
• Process is stable. 0
• Overtime costs decreasing. Jan Feb Mar Apr
• Number of late shipments decreasing.
• Floor space reduced.
5. FUTURE STEPS
• Continue improving dirt containment and control activities.
• Develop automatic unloading device to further reduce cycle time.
• Improve handling to further reduce cycle time.
• Begin activity to correct other causes of late shipments.

Figure 18-5. (Continued)