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toyota (OFF LINE DOJO (People development maps, Evidence based promotions,…
ENTRANCE FOYER
HOSHIN
5 Year site plan
Company Hoshin
Mid term plans
Department Hoshin
Visible in every Cell
No X Matrix used
SAFETY
Activities
Policy
Incident status
Strategy Plan
KPI Accident rate
CORPORATE RESPONSIBILITY PROJECTS
JUST IN TIME
Takt Time 44 Seconds
600 Engines + per shift
680 People on site
JIDOKA
Quality built in by people
Less Poke Yoke
Don't except repeat problems
Improvement daily
ANDON
Team leader tries to solve inside takt
Line stops after 1 cycle
Stop - Call - Wait
Daily defects visible in Obeya
GEMBA
Seibi
(Maintenance)
Yoedome (Energy savings)
Improvement area
Visible abnormalities
Fluctuations
5S
Toyota only use 4S
Clarly visible - Are we winning or losing today
Movement MUDA
Machines
People
Materials
Reduce parallel actions
Stable feed rates
Team leader
Kamishibai
Standard work confirmed every shift
Process control board
Daily audit checks used for problem solving
Management on Gemba every day
KAIZEN
Each person raise 2 per month
700 complete in 2018
Everyone involved all levels
OFF LINE DOJO
People development maps
Evidence based promotions
Leadership development
Standard skills training
Job rotation
First Kaizen on first day
Training methods PDCA
OTHER
Awards for best Kaizen
Chop stick game
