Toyota Rules

June 07, Ver 0

A BIG PART of ELIMINATING WASTE consists of preventing defects. Defective products entail a grievous waste of human resources, equipment, and material. And measures for eliminating waste by preventing defects are a definitive feature of the Toyota Production System. By identifying waste and eradicating it, companies can reduce their costs.
Excerpts from THE TOYOTA PRODUCTION SYSTEM -Sakichi Toyoda; Kiichiro Toyoda ,Taiichi Ohno
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Contents
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Contents
Respect of Product What Why RoP ? RoP for all functions How To ? RoP deployment Step1 RoP deployment Step2 RoP deployment Step3 3 4 5 6 24 25 26

List of Pictures and Templates

Receiving
Damaged Pallet Good Example Proper Protection Clean Containers Component Stick Out In process protection Piled Material Part Drop Clean trolley and container Secure clean holder Identified Place Incomplete Set Unnecessary Stock Reject Part Handling Tool Misuse 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Line Supply

Process

Warehousing Storage and Shipping

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Respect for Product What ?

June 07, Ver 0

To continuously improve Quality & Productivity, the workplace has to be clean and components in the right condition so that operation can be done with zero defect mind set. Respect for Product is a set of preventive rules to maintain integrity of product/component during all operations starting from suppliers to customers Rules for Respect for Product are simple to implement and a matter of common sense Application of Respect for Product rules is complementary to 5S It is the foundation stone for APS implementation Respect for product at each stage of the process is Mandatory and essentially a matter of vigilance
RoP : Respect for Product
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Why Respect for Product ?

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It gives good visibility of product/component for quality evaluation

Easy to count Easy to store & handle Easy to maintain cleanliness Easy to identify damaged product/component

It is reproducible and therefore sets standards for product handling & movement It is a necessary condition for getting Zero Defects
At each stage of the process it is essential to implement RoP to the smallest detail

End of line rejects

Parts in damaged packets sent to Customer is a logistic incident Parts not packaged correctly will lead to noise, leakage due to impact and dents, visual defects
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RoP for all Functions

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Examples of Areas where RoP is applicable for different functions

Function
R&D Project Laboratory

RoP Applicable in
Arranging for prototype, tooling & packaging design Assembly recommendation for customer Withdrawal of products for analysis Handling & re-integration in product cycle Delivery for prototype and initial samples

Purchasing Process Management

Logistics contract packaging Precaution during manufacturing

Non-acceptance of abnormal situations whatever they may be

How to ?
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RoP Is applicable across operations Receiving & Warehousing Line Supply Process Storage Shipping

Receiving*
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Damaged pallets and boxes shall not enter in the plant Properly protected against dents, shocks, dust, water, chemicals.

Damaged Pallet Should be discarded

Receiving
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Good Example
Individual parts arranged in an array, well separated

Door protects from dust, humidity and tampering

Incoming Material Bins with Cover

Receiving*
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Properly protected against dents, shocks, dust, water, rust, chemicals

Rusted Parts not acceptable

Receiving
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Dirty or damaged returnable containers must either be cleaned or discarded

Dirty and damaged container to be rejected

Clean Containers

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Line Supply
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No parts or components should stick out of the container

Not Acceptable - Parts Sticking out Good Packing Standard

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Line Supply*
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Materials supplied to the production line are properly protected

Exposed part liable to damage

Protected against scratch, dents, grease

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Line Supply
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The supply of components to the line piled together is not acceptable

Material Piled Together

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Line Supply
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A part drop on the floor is immediately scrapped

Part to be Scrapped

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Line Supply
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Clean containers

Dust & Oil stays at bins and trolley

Trolley & Bins are changed now dust and oil will not stay

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Process*
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Each part should be placed in a secure clean holder - during product and process development supports are clearly defined and validated
Part not in proper place All parts on proper holder

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Process
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Each Standard parts should be placed in an identified clean place

Product Identification for assigned storage area

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Process
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Appearance parts should be handled with clean gloves No incomplete sets of components Unless finished do not use components from other sets

For similar parts (below), use from container 2 only when container 1 gets empty

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Process
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Zero illegal stock (unnecessary stock) between workstations Specific holders /supports /packaging should be used for subassemblies stocked between two workstations

Specific holder for in process tubes Illegal Stock

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Process*
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Rejected products must also be respected : If rejected parts are not respected, then it is impossible to analyze problems Rejected parts must be properly placed in the container for analysis
Rejected parts stacked properly

Unacceptable handling of rejects

A stand to keep the rejections no metal to metal contact

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Process
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No use of tools not specified by the standard (work instruction, maintenance, ) Parts cannot be used as tools to put nuts, bolts, grease, washer other component

Improper use of tools piston rod being used as a hammer

Proper Tool being used

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Warehousing
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Good Example

Products inside the bin with separators preventing physical contact and associated damages

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Storage and Shipping

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Zero illegal storage of containers in other parts of the plant Containers should protect products from damage Damaged containers shall not leave the plant
Damaged Cartons. Stacking Rules violated Not to be shipped

Stack Height Limit

ID Labels

Handling precautions

Zone for Stacking

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RoP Deployment Step1

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Each department/line/cells evaluate the status in regard of the best practice

Status Red Conditions
No formal deployment Formal deployment is defined Communication and training done to the all employees Best Practice customized with pictures of the plant situation Application of the Best Practice is audited No example of non respect for the product Extension to suppliers and customers
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Yellow

Blue

Green

RoP Deployment Step2

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Official launch by Management communicating the objective to the site Micro training sessions with practical application in the field Each cell defines 10 rules according the Best Practice.
Operator and Supervisor should identify on their own cells the root cause which can generate defect during process operation Action plan to implement the corrective actions needed is set up and followed up These rules become a part of standards

These rules are incorporated in the workstation and line and audited during process audit
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RoP Deployment Step 3

June 07, Ver 0

Applicable to Suppliers Everything arriving in our plants from suppliers should be faultless All defective products and containers should be sent back to the supplier Product Respect rules must be integrated into the purchasing standards of products Qualification of product/process must include compliance with Product Respect rules Applicable to Customers : Project Manager should communicate to the customer recommendations for
Customer product storage and handling conditions Movement of products between the warehouse and the customers production lines Proper use of the product on the customers production lines.
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