30
c. A learning, non-judgmental, non-blaming because blaming is wasteful approach and intent will allow the re-examination of the assumptions that
resulted in the current process.
People at all levels of an organization can participate in kaizen, from the CEO down, as well as external stakeholders when applicable. The format for kaizen can be
individual, suggestion system, small group, or large group. At Toyota, it is usually a local improvement within a workstation or local area and involves a small group in
improving their own work environment and productivity. This group is often guided through the kaizen process by a line supervisor; sometimes this is the line supervisors
key role.
2.7 Basic Stability
First step in creating process that lean is reaching the elementary level of stability process. First level of stability generally defined as ability to produce the
consistent result a number of minimum percentages from time. Simpler indicator is ability to fulfill requirement of customer for product with high quality at the first time
punctually. In most cases, customer requirement not defined clearly and become one of first duty in stability step translated from Liker Meier, 2006.
Devi Adhriany Rahayu :Building Model Of Basic Stability For Productivity Improvement Journey In PT.Dow Agrosciences Indonesia By Utilizing Value Stream Mapping VSM In Production Shop Floor, 2009
USU Repository © 2008
31
Indicator of Instability Translated from “The Toyota Way Fieldbook” by Liker Meier, 2006, says,
developing stability of the process is not an end from anything. Even it is more looking like creation of a foundation for the aspect of hereinafter from process lean.
Through direct observation, an unstable process distinguished by condition following: 1. High variation in performance measurement – variation in number that
produced and also total production per hour labor. 2. Frequently alter the plan when problem happened. Including relocating
labor or let an empty position when there is an absence, removing product to other machine when there is a damage and in consequence can not produce
the planned product, and stop working in the middle of process to change to other order.
3. Almost impossible to perceive the pattern or consistent work method. 4. Corps or goods heap in process WIP which vary - sometime a lot of,
sometime a few. 5. Sequencing of operation that run independently island process.
6. Inconsistent stream or no stream also distinguished by heap WIP which vary.
7. Words use usually, basically, normally, generally, most of the time, when describing operation, followed with unless, like in Normally we do
this……unless………happening, hence we do this......... According to the character, unstable operation is often not experiencing “normal” condition in
Devi Adhriany Rahayu :Building Model Of Basic Stability For Productivity Improvement Journey In PT.Dow Agrosciences Indonesia By Utilizing Value Stream Mapping VSM In Production Shop Floor, 2009
USU Repository © 2008
32
the case of consistent method. Even, abnormal circumstance becomes normal.
8. Statement like, We trust the operator to take the decision about how work to be done this is part of wrong employees utilization understanding.
Stability is not just conditions from process that flows, however developing process that flow will assist to motivate the approach which discipline to stability -
both of them are interconnected translated from Liker Meier, 2006.
Objective of Stability The main objective of stability phase is creating base for consistency so that
fact is visible and non value added activity can be eliminated, and then create the foundation for the real improvement. This include reducing variability of level
customer demand before specifying takt time, level of customer demand and create the production process with flatten daily volume. A stable process also will have high
level of flexibility and ability to fulfill demand from customer which varies translated from Liker Meier, 2006.
2.8 Standardized Work: The Power of Consistency
