Toast Kaizen: Value Stream Mapping

2011 Shingo Prize Recipient!

In 2004, GBMP released Toast Kaizen, a short video to demonstrate the importance of direct observation in continuous improvement. It is now used around the world (in 14 languages) to help explain the true meaning of Kaizen. In reality, as viewers observe the 2004 toast-making process, they are witnessing an already improved process, one where much Muda, Mura and Muri have already been remove as the modern-day kitchen is fairly well organized already. But this is not so in most other endeavors.

According to Bruce Hamilton (the Toast Guy), “If our kitchens were organized the same way as our factories, offices and clinics, then the refrigerator would be in basement, the toaster would be in the attic and the bread would be stored anywhere there was an open space. We would be making huge batches of toast that spent most of their existence being moved and stored. And we’d see isolated departments that each added a little bit of value and a whole lot of waste, working out of sync, rarely communicating and often displeasing the customer.. Just like most business environments”

So, watching "Toast Kaizen", it’s easy to separate the wastes from the work, and in doing so make the whole job easier, better, faster and cheaper. But what if the process is not self-contained as in a kitchen. What if the process is laid out like most factories and offices? Then those material, information and production flows would be spread out all over into functional areas that would hide most of the waste. In fact, almost none of us see the whole process in our daily work, just the little piece we do ourselves. So now, GBMP offers "Toast VSM", a 2009 sequel to the original - a DVD no Lean Training Library should be without.

Come along on a toast odyssey that mimics the more typical conditions employees encounter when they attempt to value stream. Divided into two half-hour training segments, Part 1 of the lesson examines the current condition (or state) as we follow the toast-making process to understand the material and information flows. Viewers will participate in the observations and the sometimes contentious discussions about what has been observed as GBMP team travels the process upstream to expose system and process problems. You’ll learn how to capture both numeric and anecdotal information on paper, and how to achieve a consensus regarding the key points of the current condition.

Part II details the target condition (state) demonstrating how orders of magnitude improvement can be systematically identified, achieved and measured. Viewers will be introduced to a VSM Action Plan in A3 format that provides a complete analysis, reflection, improvement plan, measures and milestone tracking on a single 11x17 sheet.

Whether your process is pure factory or administrative or service-related, "Toast VSM", offers a realistic, day-in-the-life experience for lean implementers who wish to gain the full benefit of Value Stream Mapping.

GBMP videos are copyrighted and cannot to be duplicated. Posting GBMP videos on a company Intranet site is illegal and only permissible with the purchase of an annual site license. Contact Tracy Reardon at 617-527-0268 to learn about the convenience and affordability of purchasing a site license.