Toyota Kaizen Methods : Six Steps to Improvement.

280 Pages·2010·7.073 MB·English

by  Kato, Isao, Smalley, Art

Toyota
Kaizen
Methods
Six Steps to Improvement
Isao Kato and Art Smalley
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Productivity Press
Taylor & Francis Group
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Contents
Foreword
1 Introduction
2 Background of Kaizen in Toyota
2.1 History of Kaizen Methods in Toyota
2.2 The Toyoda Precepts
2.3 Training-Within-Industry Job Methods Introduction
2.4 “P-Course” Introduction
2.5 Development of Toyota’s Kaizen Course
2.6 Operations Management Consulting Division and
Jishuken Events at Tier One Suppliers
2.7 Summary
Notes
3 Introduction to Kaizen in Toyota
3.1 The Importance of Kaizen
3.2 Key Concepts
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3.2.1 The Role of a Leader
3.2.2 Five Ways to Increase Production
3.2.3 Processing Methods Affect Cost
3.2.4 Work versus Waste (Muda, Mura, Muri)
3.2.5 Cost Reduction Principle
3.3 Basic Pattern for Kaizen
3.3.1 Step 1: Discover the Improvement Potential
3.3.2 Step 2: Analyze the Current Methods
3.3.3 Step 3: Generate Original Ideas
3.3.4 Step 4: Develop an Implementation Plan
3.3.5 Step 5: Implement the Plan
3.3.6 Step 6: Evaluate the New Method
Note
4 Step 1: Discover Improvement Potential
4.1 Introduction
4.2 Kaizen versus Problem Solving
4.3 Kaizen Attitude
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4.4 Analytic Skills for Kaizen
4.5 Opportunity Awareness
4.6 Basic Methods for Uncovering Waste and Identifying
Improvement Opportunities
4.6.1 Compare Performance to Standards
4.6.2 Production Analysis Board
4.6.3 Seven Types of Waste
4.6.4 Five S
4.7 Summary of Step 1: Discover Improvement Potential
4.7 Homework Assignment
Note
5 Step 2: Analyze Current Methods
5.1 Introduction
5.2 Basic Analysis Methods
5.2.1 Work Analysis
5.2.1.1 Work Analysis Units
5.2.1.2 Training-Within-Industry Job Methods Analysis
5.2.1.3 Toyota Work Analysis
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5.2.2 Motion Analysis
5.2.3 Time Study
5.2.4 Standardized Work
5.2.5 Machine Loss Analysis
5.2.5.1 Equipment Breakdowns
5.2.5.2 Equipment Changeover
5.2.5.3 Equipment Cycle Time
5.2.5.4 Minor Stops
5.2.5.5 Scrap or Rework
5.2.5.6 Startup or Yield Losses
5.2.6 Material Flow Analysis
5.3 Summary
5.4 Homework Assignment
Notes
6 Step 3: Generate Original Ideas
6.1 Introduction
6.2 Key Concepts Regarding Idea Generation
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6.2.1 Common Roadblocks to Creativity
6.2.1.1 Force of Habit
6.2.1.2 Preconceptions
6.2.1.3 Common Sense
6.2.1.4 Not Invented Here Syndrome
6.2.1.5 Emotion
6.2.2 General Advice Regarding Creativity and Teams
6.2.2.1 Separate Idea Generation from Judgment
6.2.2.2 Generate as Many Ideas as Possible
6.2.2.3 Think from Different Angles
6.2.2.4 Combine Ideas with Others
6.2.2.5 Review Previous Analysis
6.2.2.6 Synthesis Ideas
6.2.3 Methods for Developing Ideas
6.2.3.1 Osborn’s Checklist
6.2.3.2 Rules for Motion Economy
6.2.3.3 Further Suggestions for Manual Work
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6.2.3.4 Review 5W 1H and ECRS
6.2.3.5 Brainstorming
6.3 Summary
6.4 Homework Assignment
Notes
7 Step 4: Develop an Implementation Plan
7.1 Introduction
7.2 Key Concepts
7.2.1 Six Points for Consideration in Planning
7.2.2 Implementation Cases and Planning
7.3 Summary
7.4 Homework Exercise
8 Step 5: Implement the Plan
8.1 Introduction
8.2 Key Concepts
8.3 Summary
8.4 Homework Exercise
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