Page 86 - The Toyota Way Fieldbook

Chapter 4. Create Initial Process Stability 63

at it and ask, “What does it look like?” Perhaps the answers will be, “Messy, lots
of moving around, lots of crisscrossing, backtracking, etc.” Visually, people will
see that the work flow is not good. If you are fortunate to have good work flow
at this stage and do not see a messy picture, you’re ready to go a level deeper
and analyze for smaller hand motions.
Figure 4-1 shows a completed waste analysis, including the work steps, the
work and walking time (in seconds), and the pictorial view of the operator work

Work Step Work Time Walk Time
1. Pick up A Bracket 1 2
2. Load Fixture (walk to fixture) 6 2
3. Pick up B Bracket 1 3
4. Load Fixture 5 3
5. Pick up Side Support 1 1
6. Load Fixture 3 1
7. Pick up Stiffener 1 2
8. Load Fixture 8 2
9. Pick up Brace 1 3
10. Load Fixture (start over) 5 3
Total Seconds 32 22

Fixture
A B
Brace Stiffener 2
10 4 Bracket Bracket
9 7 8 6 1 3

5
Excessive walking time!
Side
Backtracking and criss-
Support
crossing walk paths

Figure 4-1. Completed waste analysis