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QCD 101 | For the Shipping Area

Visualization Clearly Identify: what, how many pcs, where to, what time and which track. Clearly Identify: from which line or store, when, and how many pcs are pulled-in. Clearly Identify: shipping preparation hourly status. Visual Control Confirm the hourly status per the plan, and if any abnormality (delay) was observed, identify the cause and clearly […]

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QCD 101 | Finished Goods Store

Visualization Locations should be designated by products and production lines.  Inventory situation including inventory plans should be clearly visible. Visual Control Check the inventory to see if the amount meets the inventory plan.  If abnormality was observed, identify the cause and describe the counter measures on a control board. Supervisors should confirm the content on […]

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Study Guide – Toyota Way Fieldbook – VSM

Starting the Journey of Waste Reduction Part 3 Chapter 3 – VALUE STREAM MAPPING APPROACH By Swati Jadhav Recently I had a chance to read the book called The Toyota Way Fieldbook, by J. Liker and it changed my viewpoint towards Lean methodology. I used the guidelines provided by the book for the Value stream […]

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Toyota Way Fieldbook – “Study Guide”

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Overall, we have found the Fieldbook to be a great tool for those interested in “middle of the road” lean implementation.  Not “Big Picture” nor “Fine Detail”. For those interested in digging a little bit deeper for work or school… or for the Engineering Intern looking get a jump on a future career, we offer the […]

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8D Problem Solving

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The eight-step Ford methodology for problem solving. D0: Plan—Plan for solving the problem and determine the prerequisites. D1: Use a team—Establish a team of people with product/process knowledge. D2: Define and describe the problem—Specify the problem by identifying in quantifiable terms the who, what, where, when, why, how, and how many (5W2H) for the problem. […]

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Taiichi Ohno Quote

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“Why not make the work easier and more interesting so that people do not have to sweat?  The Toyota style is not to create results by working hard. It is a system that says there is no limit to people’s creativity.  People don’t go to Toyota to ‘work’ they go there to ‘think’” – Taiichi Ohno

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5S System

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A system designed to organize and standardize a workplace and consisting of five component parts: Sort, Set in Order, Shine, Standardize, and Sustain.

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Andon

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Andon is a Japanese term related to manufacturing that refers to a system that notifies management, maintenance, and other employees of a quality, quantity, or process problem within a process. The signboard that shows this problem is located centrally, and signals using lights that indicate the specific workstation that has the problem and requires attention […]

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