Page 76 - The Toyota Way Fieldbook

Chapter 3. Starting the Journey of Waste Reduction 53

be initiated within the process. If the operation is independent of others, the flow
phase is not initiated until “connection” is made with additional operations.
This is “multiprocess connected stability.” Connecting two or more individual
operations, cells or lines, may create new stability challenges that need to be
corrected prior to advancing.
Finally, as all processes pass through the first phase of stability and reach a
capability level to support connection, they are connected across the entire
value stream. This is “Value Stream Connected Stability.” The initial process of
moving through the Continuous Improvement Cycle to achieve system-wide
stability and flow can take years of effort.
We generally recommend creating a fully connected value stream within your
own plant or operation before moving out to your customers and suppliers.
Once you have your house in order, you can begin to work with suppliers to
help connect them to your lean processes. The same approach applies. They
need some level of internal stability before it is valuable to connect their opera-
tions to yours through pull systems. And then you still face a problem if your
customer is not lean and does not understand the Toyota Way philosophy.
Educating your customer is certainly challenging since they hold the purse
strings. But this can be done in small steps, and when they see the benefits,
they’ll want to learn more and you will become even more valuable to them.
The ultimate goal is a connected lean enterprise.
In sum, waste reduction sounds easy but there is actually much to it. The pur-
pose is not to simply make one pass over your operation to seek and destroy
waste. The purpose is to create a connected value stream in which all team asso-
ciates are being forced to think, solve problems, and eliminate waste. In the chap-
ters that follow we will go into more detail on the process of creating connected
value streams.

TIP

Multitask for Speedier Results
The time frame for creating a connected value stream can be
accelerated by working in multiple process areas simultaneously.
Think of it as building a chain, link by link. After each link is
stable, the connections between them can be made. After a value
stream is connected, an incremental reduction in pitch time (small
leveling) within the entire value stream will cause the weakest
link to “break” and become unstable again. This is the link that
will require focused attention and a return through the continuous
improvement cycle.