Page 90 - The Toyota Way Fieldbook

Chapter 4. Create Initial Process Stability 67

Line Support

Material Storage

Shipping

Figure 4-4. Non-value-added activities consolidated

In addition to establishing an available resource, the consolidation of
non-value-added tasks creates a cyclical, repeated process for the pickup
and delivery of material. This activity should be performed on a timed
cycle, or pitch. This pitch is defined based on the needs of the operations
and other factors and is the foundation for standardizing the movement
of material.
Standardizing this activity includes what will be done, who will do it,
and when it will be done. It is important that these tasks be cyclical
and repeatable so the foundation is established for standardization.
Once it is established, additional improvements can be added, such
as specific containers and delivery carts, and racks for presenting material
to the operator. Many companies get the cart before the horse and
attempt to create the devices (carts, racks, containers) before they
establish the process—a standardized repeatable method. Once the
process is standardized we can then look for opportunities to reduce
the labor required by rebalancing the work among other operators.
Ultimately we usually find labor savings both in direct labor and in
material handling.