Understanding Lean Mistake-Proofing in Toyota Production Systems
Discover the principles of Lean Mistake-Proofing as applied in Toyota Production Systems. Learn about identifying and eliminating waste, different types of waste, mistake-proofing methods, and the importance of 5S methodology in preventing errors. Explore how Standard Operating Procedures play a key role in ensuring tasks are carried out correctly every time.
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Lean: Mistake Proofing Toyota Production Systems Lab Grade 6-8
| 2 Mistake Proofing Industrial engineers want to make things better by preventing problems before they start. In order to prevent problems, first we must identify problems or areas of waste. The Japanese word for waste is Muda which is a term that is used a lot when talking about Lean.
| 3 7 Types of Waste Remember the Acronym TIMWOOD Transportation Inventory Waiting Overproduction Overprocessing Downtime
| 4 Waste Makes Mistakes! When we let waste occur it creates problems that we now must go and fix. By eliminating sources of waste we prevent problems! We eliminate waste through Kaizen bursts and process improvement activities like 5S. Then, we need to make sure it does not happen again, that s where Mistake Proofing comes in.
| 5 Mistake Proofing Mistake Proofing methods help to prevent mistakes from happening. So no matter who does the job or task, they can all do it the same way and not create any problems. There are many different types of Mistake Proofing.
| 6 Mistake Proofing Method - 5S 5S is a method allows us to organize, and clean our workstation, and eliminate unnecessary mistakes by . 1. Sort 2. Set in order 3. Shine 4. Standardize 5. Sustain
| 7 5S Example: Workstation 5S makes sure everything is clean, organized and easy to find. For example, the picture below shows a very messy workstation and a 5S workstation.
| 8 Questions: 5S Workstation Examples The 5S workstation is very organized and everything in the area is where it should be. What forms of waste do you think organizing this area gets rid of? 1. 2. 3.
| 9 Mistake Proofing Method Standard Operating Procedure (SOP) Standard operating procedures list the steps needed to complete a task. Having this list available to the worker at their workstation helps them do their task correctly every time since the instructions are always there if they need to check!
| 10 SOP Example Here is a fun example, where a Standard Operating Procedure was created for the Hokey Pokey Dance! See how all the steps are listed in a way that is easy to understand and anyone can follow along?
