8-Step Procedure for Defect

Recurrence Prevention Activity

by Toyota veteran Sadoa Nomura

1 Actual defect
check
Immediately conducted
by the team leader (TL)
6 Standardization and
horizontal deployment
Conducted by TL
during the next day

Actual defective parts are checked to identify Determination of work procedures and basic
the process where the defect occurred. rules
Is there any work standard? Do they

2
understand it? Is just following it acceptable?
Stock check → If not, revise it immediately.
Conducted by TL
& sorting immediately If not available, create it immediately.
Make it simple to enable them to
Whether there are any other parts having the same
understand it at a glance.
defect in the stock shall be checked to make sure of
the beginning and ending of the defect occurrence. Listing of similar processes/items and
implementation of horizontal deployment

3
Zero defects cannot be achieved only by
improving the process where the defect
Cause Implemented by TL occurred.
investigation within the day

7
The cause investigation is conducted through GENCHI
GENBUTSU check. Also, the cause is investigated through Education Conducted by TL
interviews with the workers in the relevant process. and training during the next day

4
Education is to teach people what is
standardized.
Countermeasure Implemented by TL Training is to enable workers to do what they
implementation within the day
were taught correctly in real work.
Against the causes of defect occurrence and → TL must make them promise to do what
outflow, respective countermeasures are they were taught.
implemented. Those actually implemented are
written in the sheets on the Asaichi plastic board.

5 Asaichi report
Reported by TL at the
8 Daily management Checked by TL
every day
next Asaichi meeting TL checks whether members are actually
The relevant TL explains the cause and measures doing as they were instructed
to all the members in an easy-to-understand Check members’ work through GENCHI
manner, writes down any instruction or guidance GENBUTSU observation and make prompt
on the sheet, and conducts follow-up activities. corrections to defects if any.

Learn more from Nomura in his new

book available now at lean.org/nomura