Toyota Industrial Engineering - 8 Step Model

Clarify the problem

Breakdown the problem

Set a target

Analyze the root cause

Develop countermeasures

See countermeasures through

Evaluate both results and process

Standardize successful processes

https://blog.gembaacademy.com/2009/02/22/tbp_toyota_business_practice/

Toyota Industrial Engineering - 8 Step Model - In Detail

Clarify the problem

Understand the need and scope of the industrial engineering study. Discuss with many. Shop floor operators, supervisors, engineers and managers. Collect the drawings and process plans. Study the process on the shop floor. Prepare process charts for the current practice.

Breakdown the problem

Identify the operations. Identify elements in each operation. Collect data for each operation in operation information sheets.

Analyze the root cause

Analyze the reasons for the problems or scope of improvement based on the current technologies and known best practices.

Set a target

Develop targets for improvement to guide design and development of countermeasures to the problem or improvement.

Develop countermeasures

Design and develop the countermeasures. Detailed engineering can be done by IE department or can be given to internal engineering departments or can be given to external consultants.

See countermeasures through

Do the trial of new methods.

Evaluate both results and process

Assess the new process. Assess the results. Take the opinions of all stakeholders.

Standardize successful processes

Develop the new process and make it the new standard process.

Continuous improvements to the new standard process keep on occurring based on the ideas of operations personnel.  Major studies by IE teams also keep taking place on periodic basis.