Toyota

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TOYOTA MOTOR MANUFACTURING:

Genchi Genbutsu – ‘Go Look Study’

WHO

Weld Manager

WHAT

Genchi Genbutsu

WHERE

Toyota Manufacturing UK, Derby

WHEN

Manager undertakes 26 per year

HOW

The monitoring sheet for the area is produced periodically outlining topics to be monitored The Manager is joined by the Group Leader and the Safety Specialist Documentory monitoring is carried out in the group meeting room The team then goes on to site to carry out ‘lineside’ checks Brief feedback is given at the end of the activity to the Group

“When there is an W accident senior management get involved. It may be the Chairman. He says “let’s go together and understand.” That’s very powerful to members – it shows Toyota cares, and they feel valued.” “The focus has to be on sustainability of management systems.” Tim Freeman, Weld Manager

PURPOSE

before - To confirm the group is following the ‘standard’ - To maintain impetus - To maintain ownership

after

Genchi Genbutsu is a key element in Toyota Uk’s approach to continuous improvement. It is the method used by management to go to the source, to find the facts to make correct decisions. One application of Genchi Genbutsu used routinely by management is monitoring. There are two sections: ! Group Management – checks that confirm the group has good accurate visual confirmation of their injury and ill health prevention activities - current focus activities are: fire wardens; fire refresher training; posture confirmations; member concern tracking; health and safety guide cards available to Members. ! Lineside Confirmation – checks to confirm the workplace is in good condition. Current focus activities are: 4S (housekeeping); chemicals; machinery/equipment; fire extinguishers; use of PPE. Each are checked against the Toyota ‘standard’ of working in a safe and healthy way which all staff have been trained in and are aware of. This monitoring activity focuses on the effectiveness of the...