To-Be” Flowchart Analysis

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  • 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.

Process Improvement Categories

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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.

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