toyotas 8 steps to problem solving

Toyota’s 8 Steps ToPractical Problem Solving

Presents

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No frills

Simple

Lean Rooted

Kaizen Boosting

No Gimmicks

Proven method over time developed by one of the most successful companies of our time.

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Mind Over Matter

Facts

Data

Experience

Common Sense

Are all used to form Logical & Rational Solutionsto your organization's problems and objectives.




What’s The Problem?

First things First...

Define what your organization considers a problem:

Any deviation from the standard

Gap between the actual condition and the desired condition

Any unfilled customer need




Clarify The Problem

Decide why it is a problem

Determine the benefits to solving the problem

Consider how it fits into the business as a wholeand the effects it will have on current goals

Go SEE the problem first hand!

STEP 1

(Also referred to as the GEMBA Walk - see ourGemba Walk 101 on Slideshare.net)


問題を明確にする



Break Down the Problem

Time to get detailed and specific

Break down big problem into small problems

Go SEE each small problem up close!

Study & Analyze inputs & outputs of the process

Prioritize efforts based on results

STEP 2


問題をブレイクダウンする



Set the Target

Time for Commitment

Focus turns to what is needed to complete project

How long will it take?

Set target dates that challenge staff,but don't hinder other improvement efforts

STEP 3


達成目標を決める



Analyze the Root Cause

Identify the factors that cause the problem

Generally more than one

Consider and address any and all potential root causes

Go and SEE root causes in person!

STEP 4


真因を考え抜



Develop Countermeasures

Teams develop countermeasures to removeroot causes

Develop as many as possible that directly address root causes

Narrow down to most practical and effective based off your target

STEP 5


対策を立てる



Implement Countermeasures

See countermeasures through with clear detailed plan in a timely manner

Open communication is vital during implementation

Seek ideas and feedback to see what is and isn't working

Focus on one countermeasure at a time to effectively monitor them

STEP 6


対策をやりぬ



Implement Countermeasures (cont.)

“Anyone who has never made a mistakehas never tried anything new.”

--Albert Einstein

Mistakes happen, it's ok!

Continue to work through the process

Persistence is key

STEP 6


対策をやりぬ



Monitor Results and Process

Some countermeasures require more than one attempt to get right

They may need modification and adjusting

Determine if intended outcome was result of countermeasure or a fluke

Always room for improvement in the process if you have the tools in place to recognize them

STEP 7


結果とプロセスを評価する



Standardize and Share Success

Set new processes as the new standard

Share results with organization

Reflect on what you've learned

Address ALL unresolved issues

STEP 8


成果を定着させる



Incorporating the PDCA Deming Cycle

Steps 1 – 5: Planning what you're going to do

Step 6: Doing what you've planned

Step 7: Checking the results

Step 8: Act on your results to set new standard


The Eight steps work hand in hand with PDCA



On to the Next One

Continuous improvement never stops

Move on to the next problem seamlessly

Continue to work towards perfection





We’ve got you covered.Creative Safety Supply works with companies both

large and small to help them with theirArc Flash Labeling, Software and Signage needs.

We also carry a host of PDCA, Lean, 5S, 6S Kaizen,

Kanban and Continuous Improvement products.

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