Page 18 - Toyota Annual Directory 2020-2021

RECURRENCE PREVENTION WITHIN TEAM
1. TEAM year 2020 highlights
During the arm 2020, we introduced the recurrence prevention (rp) concept within team to raise further awareness on past critical flow outs (cfo’s) towards our manufacturing plants, spread lessons learned from those concerns and explain how we tackle them in order to prevent their re-occurrence.
RP background: CFO’s
CFO’s are major quality problems that can occur
at a supplier plant and flow out to a Toyota Manufacturing plant. Depending on which stage a CFO is found, we must take immediate field actions to protect our customers. These actions can be stop shipment in yards, pre-delivery corrections at dealers, or even recalls at end users (in worst case). As TME Purchasing, we are enhancing RP activity as we continue witnessing field actions whereas our target is to achieve 0 CFO.
RP purpose: improve the way we work
RP is not only a philosophical part of the Toyota Way, but also a strong problem-solving tool to transform past failures into learnings, with a positive side effect to increase competitiveness. It simply consists of improving the way we work to prevent same or similar concerns from re-occurring in the future.
The methodology relies on four steps at the end of which TME Purchasing ensures lessons learned are spread across our supply base (Yokoten):
Number of field actions:
10 5
0
CY17 18 19 20 philosophical
TME TARGET = 0 CFO
REFLECTION
PROCESS ROOT CAUSES RP MEASURES ANALYSIS INVESTIGATION PLANNING
Learning cards sharing & best practise exchange
Last TEAM year, we focused more on the Yokoten part of RP process, through the concept of learning cards sharing from three previous CFO cases, and best practise discussion during Core Group meetings. The aim of our learning cards is to share systemic root causes & countermeasures that led to past critical concerns, so that TEAM suppliers can verify if there are any weaknesses in their job processes and take the necessary steps to prevent same or similar problems. In addition, suppliers could benefit from best practices, by sharing practical examples of their work instructions and other internal quality processes documentation.
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YOKOTEN