How Toyota lean production is to analyze the problem?
Toyota lean production, the management personnel in the field, having problems resolved immediately, can not be resolved to stop the line, everybody have a lot of pressure, because no one wanted to own station stop line of reason, to solve the problem here is between to the question about to complete in order to prevent recurrence.
Toyota, the problem is divided into three layers:
1. To immediately resolve the problems in the field
2. to identify the root cause of the problem and thoroughly eradicate
3. giving top priority to find out why a similar problem and get rid of in order to eradicate similar problems.
They used a Toyota extremely simple method to find a reason. Why ask five consecutive method, which is a continuous process thimble questions. The method is in the field for the continuous question asking why until you find the truth because only. Here I would like to invoke that Ohno very familiar example again:
"Why did the machine stop?"
"Because of overload, the fuse is broken."
"Why overload?"
"Because of insufficient lubrication bearing part."
"Why lubricate enough?"
"Because the lubricating oil pump drain not come."
"Why do not drain oil come?"
"Because oil pump wear, loose."
"Why wear it?"
Because there is no filter is installed, entering the iron. "
Why not install a filter? "
To finally find is not installed filters cause the machine to stop, this is the real reason.
Q. Why is this continuous five-seeking technology due to the specific circumstances and Toyota are inseparable. This requires:
1. persistent, roots question for the end of the chase spirit. This quality is not out of the training and learning but requires a certain cultural background. Few other nations have this (internal) Japanese national unity, obedience, perseverance, seriously, almost in the "Yu Zhi" spirit.
2. Solidarity and mutual assistance forms. This method is simply to find because of a culture, because it requires everyone to abandon selfish, forget self and dedicate investment. Imagine if someone selfishness of a move - to find the real discovery is due to their own mistakes caused, it will not be against me are not more things I will arrange for it it's not my own duties so ah ......!!! argumentative impossible. So this technical questions to abandon selfishness, from cultural and organizational let the full trust among employees, understanding, integration. It is also the most difficult.
- Forced result JTT. Because the JIT is not in stock, you need to zero bad production, so production can not have a failure, you need to get rid of all the problems that may affect the production, even if you have a problem is a small problem could not hide, everybody had to try forcing down discover the true reason, to get rid of all problems.