A3 Toyota 8
A3 Toyota 8
A3 Toyota 8
1. WHAT IS AN A3 PROJECT?
An activity that
(a) supports achievement of the continuous improvement objectives
(b) requires > 20 hours dedicated man-hours
(c) has an A3 worksheet
2. WHERE DO A3 PROJECTS COME FROM?
All functions & all personnel entitled to propose projects
Derived from e.g. continuous improvement objectives or VSM or other business critical source
e.g. compliance requirement or safety requirement
All projects pre-screened by snr managers prior to proposal for the master list
The master project list is maintained by the continuous improvement facilitator
3. A3 OBJECTIVE
To provide a one page (A3, 420mm x 297mm) summary of a programme, project or problem,
for the project team & relevant personnel within the organisation
4. WHY?
Encourages brevity & sharpness of thinking
Tells a logical story on one sheet for all viewers
Provides a common organisation-wide format for all programme, management, project
managment & problem solving activities
5. WHO?
Team leader of the programme or project, or process owner of the area under review
6. HOW?
Completion of the standard A3 Template. The template usually consistes of 7 to 9 boxes with
standard input requirements, that follow the 8 stpe path. The template is modified to suit
individual projects.
What is the size of the problem? What data do I have? What are the SIPOC, process mapping, spaghetti
mapping, data collection, run chart, bar
component parts of this problem? How much will I address at this point?
chart, histogram, box plot
What outcome do I want? Visualise the desired results. Using the data, set a Goal setting. Agreement with
measurable and realistic goal. stakeholders on outcome
Brainstorming
List as many potential countermeasures as possible. Identify an effective
countermeasure that directly addresses the root cause.
Team discussion
Action plan
Select the most practical and effective countermeasure. Create a clear and
detailed action plan. Implement quickly.
Gantt chart
Document the new process and set as new standard. Share the new
standard through Horizontal deployment. Reflect and celebrate success. Standard work
Start the next Improvement!
A3 No. and Name Team members (name & role) Stakeholders (role & department) Company objective
1. 1.
2. 2.
Team Leader (name & 'phone ext) 3. 3. Start date & planned duration
4. 4.
1. Clarify the problem 4. Analyse the Root Cause 7. Monitor Results & Process
Is:
Is not:
Problem statement:
5. Develop Countermeasures
Countermeasure Impact on target
1
2
6. Implement Countermeasure
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Toyota 8 step A3
A3 No. and Name Team members (name & role) Stakeholders (role & department) Company objective
A3-12345 Toast making process 1. Tom, process operator 1. Mary, Bruce's wife Domestic harmony
2. Dick, Production tead lead 2.
Team Leader (name & 'phone ext) 3. Harriet, QC team lead 3. Start date & planned duration
Bruce, master toast maker ext. 12345 4. 4.
1. Clarify the problem 4. Analyse the Root Cause 7. Monitor Results & Process
Is: The Kitchen, toast making process for wife
Is not: any other part of the house, any other
cooking process, the washing up
Problem statement:
Bruce's time and resources (bread, butter &
energy) are being wasted in the process of
making toast that fails to meet his wife's
requirements. As a result the process needs to
be repeated.
1 Ask the customer what she wants Correct inventory, no dumping, RFT 100% Domestic harmony is increased :)
2 Move toaster near plates & bread Distance: minus 12 metres 1. Lean is a different way of looking at things.
Focus on the process, and WASTE in the
Time: minus 1 min process, not the individual carrying out the
3 Have spreadable butter ready Distance: minus 6 metres process
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IS /IS NOT ANALYSIS
Used to develop a problem statement and define the scope of a project.
IS IS NOT
Description NOTES
(Observation): (Observation):
What processes?
Who is affected?
Is there a pattern?
S Specific
M Measurable
A Achievable
R Realistic
T Time bound
Cause and Effect Diagram
Prepared by: _________________________