- Use the two selected As-Is process flowcharts from Week 2 for reference.
- Recommend process improvements using the categories selected and benchmarked against Toyota.
- Map the new improved To-Be processes.
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Process Improvement Categories |
Definitions (Identify and Explain) |
Toyota (Best Practice) Description |
|
Reduced Lead-Time / Cycle-Time |
Lead-time – the total amount of time that it takes to produce a product or service, from the time of order placement to the time of customer delivery Cycle-time – the amount of time it takes to complete a process step in an operation cycle from beginning to end |
Toyota has created an integrated Kanban system, using the inventory pull system. Takt Time (rate at which a finished product needs to be completed to meet customer demand) is clearly defined to set expectations. Additionally, a single piece flow (working on one item at a time) is used to eliminate wait time between operations. |
|
Improved Quality |
Improvement of quality to internal metrics, reduction in quality defects that reach the customer. |
Quality checks have been built into each process with instructions for standard work practices. Inspections may be completed throughout the process, with an ultimate final inspection. “Poka-yoke” systems are used to prevent or correct errors. |