Details

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Toyota Way: A3 Thinking Process

Duration: 2 Days

Introduction

This training program provides an overview of the concept and procedures for developing an A3 report with strong emphasis on the thinking how Toyota solves problems, creates plans and get new things done while developing an organization of thinking problem solvers.

Course Objectives

This interactive and practical course will provide participants with the skills and knowledge of Toyota A3 methodology and towards the end of the session, participants should be able to:

• Understand the concept of Toyota A3 thinking with emphasize on PDCA Cycle
• Use the basic types of A3 reports and templates
• Use A3 thinking to problem solving, develop critical thinking and build consensus within organization

Key Content

Module 1: Introduction

• What is Toyota Production System?
• Toyota Way Principles
• Importance of Root Cause Problem Solving
• Understanding Plan Do Check Act Cycle

Module 2: Waste Identifications

• 7 'deadly' wastes - TIMWOOD
  • Transportation
  • Inventory
  • Motion
  • Waiting
  • Over processing
  • Over production
  • Defects
• Value added/ non value added

Module 3: Tools & Techniques

• 7 QC Tools
  • Check Sheet, Pareto Chart, Fishbone Diagram, Scatter Diagram, Histogram, Control Chart, Graph
• Brainstorming
• Why Why
• 5W1H

Module 4: A3 Report

• What is A3 report?
• A3 report format

Module 5: 7 Elements of the A3 Thinking Process

• Problem Definition
  • Background
  • Specify Problem
  • Ideal State - Current State = Problem
• Problem Description, goal setting
  • Quantify the problem- Who, What, When, Where, How, How Much
  • Set goals (stretch)
• Root Cause Analysis
  • Identify points of cause
  • Identify root cause
• Develop Countermeasure,Corrective and Preventive Actions
  • Corrective actions
  • Preventive actions
• Implement, Corrective and Preventive Actions
  • Executes
• Validate Effectiveness (verifications)
  • Confirmed if goal (s) achieved
• Standardize and share learnings

Target Audience

Manufacturing, Process, Product, Device, Test R&D, Quality Assurance, Assembly, Managers, Engineers & Senior Technicians who are involved in the improvement, characterization, control and maintenance of manufacturing and engineering processes.

Methodology

Interactive lectures, case studies, small group activities, discussions, exercise, experiential learning and presentations.