Standardized Work and Yamazumi (STD Work) –  We will discuss in detail how to write a standardized work chart using the major steps, work sequence, and takt time.  We can incorporate time studies practices in order to effectively document the “elemental” work within a work sequence.  We can assist team members in creating effective Yamazumi boards (visual process bar graph) showing potential bottlenecks, overburden and unevenness within work cells.  We will provide the templates for the standardized work breakdown.

A3 Writing / Problem Solving Theme Reports – provides the team member with tools to create a summarized document of their problem, proposal or status report in order to share the “need to know” information about their report to others involved.  We consider it the “lean approach” to communication, saving time in reading a multi-page report versus a one page document.  The report format we provide will follow the 8 step problem solving approach taught in TBP.

Visual Floor Mgmt System) - is a visual control system that aligns shop floor management and team member developmental activities to align their daily activities to achieve company hoshin targets (KPI’s):

·         Ensuring foundational skills and Standardized work are in place

·         Promoting effective communication, creating the environment to:

-         Address abnormal conditions through TBP problem solving

-         Determine needed support and resources

-         Develop team members

Job Instruction Training (JIT)- or TWI _ Training within the industry  provides the team member a systematic approach to training new or existing team members using a 4 step method.  Within the 4 steps we break down the job into major steps, key points and reasons.  This process allows the team member to learn their jobs incrementally giving them the needed repetition to feel comfortable with the process in order to continue building as they master all steps.  It also gives the team member on-going coaching and feedback if issues may arise during the training session.  We provide the templates for breaking down the job.

Meeting Facilitation– this process provides the team members with a systematic approach to conduct an effective meeting.  The meeting is broken down into 4 steps, giving team members certain tools to incorporate throughout each step keeping the meeting on task.  This approach provides a foundation for team members to practice their values while developing their teamwork and communication skills.

Quality Circles(Problem Solving Teams) and Visual Tools – Quality Circles are team based problem solving activities enhancing team member skills in teamwork and group communication.  The teams are taught to utilize the TBP 8 step format to create an A3 and to incorporate the tools of Meeting Facilitation to keep the teams on task allowing for effective use of their limited time.  We also incorporate and teach various visual control tools such as:  Line graphs, check-sheets, pareto charts, pie charts, radar charts, and fishbone in order to visual the data collected within the problem solving activity.

On the-Job-Practice (OJP) – This is a 4 step approach to team member development through “supervisory mentoring” putting the Toyota Way and Toyota Business Practices into practice.  This approach should give insight to the need of the supervisor to mentor and support their subordinates effectively developing those needed skills for long term company sustainability.  It allows team members to pass on their knowledge to others and understand their people well enough to create stretch targets for learning while align their activities to the company hoshin and KPI targets.

Myers-Briggs ® Personality Type Testing- This gives team members and opportunity to learn about their own personality type as well as understanding the 15 other types of people in the world with approaches to improve the way they lead and develop people.  We go in depth with the 8 metal functions broke down from each specific type code in order of preference.   This instrument is great for individual development as well as team and company development.

Land-cruiser Manufacturing Simulation- This simulation provides a “real-life-hands-on” approach to the manufacturing process that the team member initiates improvements on.  This simulation brings to life all the elements taught above including:  TPS, STD work, JIT, PDCA, TBP and A3 activities using the Land-cruiser process to facilitate the hands-on learning.  We become facilitators at this point allowing the team members to make the majority of decisions in regard to each work cell.  Depending upon the selected training package we can provide the land-cruiser components.