Page 8 - The Toyota Way Fieldbook

vi Contents

Developing a Current State Map 42
Understand Your Objectives When Mapping the Current State 43
Limitations of the Value Stream Mapping Approach 47
Creating Flow Step by Step 49
Sequential and Concurrent Continuous Improvement 52
4. Create Initial Process Stability 56
First Get to Basic Stability 56
Indicators of Instability 57
Clearing the Clouds 58
Objectives of Stability 58
Strategies to Create Stability 59
Identify and Eliminate Large Waste 60
Standing in the Circle Exercise 60
Standardized Work as a Tool to Identify and Eliminate Waste 61
5S and Workplace Organization 64
Consolidate Waste Activities to Capture Benefits 65
Improve Operational Availability 71
Reduce Variability by Isolating It 74
Level the Workload to Create a Foundation for
Flow and Standardization 77
5. Create Connected Process Flow 80
One-Piece Flow Is the Ideal 80
Why Flow? 81
Less Is More: Reduce Waste by Controlling Overproduction 83
Strategies to Create Connected Process Flow 89
Single-Piece Flow 89
Key Criteria for Achieving Flow 91
Pull 94
Complex Flow Situations 98
Pull in a Custom Manufacturing Environment 100
Creating Pull Between Separate Operations 102
Flow, Pull, and Eliminate Waste 108

6. Establish Standardized Processes and Procedures 111
Is Standardization Coercive? 111
Standardized Work or Work Standards? 113
Objective of Standardization 114
Strategies to Establish Standardized Processes and Procedures 117