Page 9 - The Toyota Way Fieldbook

Contents vii

Types of Standardization 118
Quality, Safety, and Environmental Standards 119
Standard Specifications 120
Standard Procedures 121
Myths of Standardized Work 122
Standardized Work 124
Standardized Work Documents 126
Some Challenges of Developing Standardized Work 131
Auditing the Standardized Work 134
Standardized Work as a Baseline for Continuous Improvement 135
Takt Time as a Design Parameter 136
Importance of Visual Controls 139
Standardization Is a Waste Elimination Tool 141
7. Leveling: Be More Like the Tortoise Than the Hare 145
The Leveling Paradox 145
Heijunka Provides a Standardized Core for Resource Planning 146
Why Do This to Yourself? 147
Smoothing Demand for Upstream Processes 148
How to Establish a Basic Leveled Schedule 151
Incremental Leveling and Advanced Heijunka 157
Incremental Leveling 157
Points of Control 158
Point of Control for Managing Inventory 158
A Leveled Schedule Dictates Replenishment 159
Slice and Dice When Product Variety Is High 161
Leveling Is an Enterprisewide Process 166

8. Build a Culture That Stops to Fix Problems 171
Developing the Culture 172
The Role of Jidoka: Self-Monitoring Machines 177
The Problem-Resolution Cycle 178
Minimizing Line Stop Time 182
Build Quality Inspections into Every Job 184
Poka Yoke 186
Creating a Support Structure 195
9. Make Technology Fit with People and Lean Processes 198
Back to the Abacus? 198
What Do You Believe About Technology, People, and Processes? 200