Process analysis · Learning to see
Capture the current condition of a welding and assembly line (fuel tank) following the Toyota guideline – in five steps: (1) graph the output, (2) calculate the customer takt and the planned cycle time, (3) analyse the work patterns (block diagram, output cycles, observations), (4) check the equipment capacity, (5) calculate the core work content. Change the inputs – takt, cycle time and staffing need recalculate live. At the end everything comes together in the storyboard with the T-chart.
Process key figures
Calculated live from your inputs – the heart of the analysis.
Graph the output
Pieces per day against the planned quantity – this makes deviations and fluctuations visible.
The output is not stable and mostly below plan; missing quantities are made up at the weekend (partial shift on Saturday). First insight: hard to plan – but countermeasures are still premature at this point.
Calculate customer demand & planned cycle time
Customer takt = how often the customer pulls a part. Planned cycle time = slightly faster, to make up for losses.
Inputs
Losses = changeover time + unplanned downtime + scrap + rework.
Calculation
Analyse the work patterns
Block diagram of the process steps, measured output cycles at the end of the line and noted observations.
a) Block diagram of the process steps and their sequence
b) Output cycles – at the end of the line
c) Note observations
Check the equipment capacity
Is the machine cycle (incl. load and unload) fast enough for the planned cycle time?
Machine times
Machine time = machine cycle + load/unload. If it is above the planned cycle time, the capacity is not sufficient.
Calculate the core work content
Sum of the lowest repeatable cycle times ÷ planned cycle time = theoretically required number of operators.
20-cycle check · lowest repeatable cycle time
Storyboard on the shop floor
Everything brought together – the T-chart belongs in the “Metrics and trend” column.
Video companion · Questions & answers
All terms and calculations from the video – in plain language. Click a question to open the answer.
Key terms explained +
The Toyota process analysis first creates a clear understanding of the current condition before anything is improved. Here are the most important terms in plain words:
How saving works +
This HTML file is your document. Everything you enter is saved in this very file, just like a Word document. If you share the file, it includes all your analyses.
Save (green button or Ctrl+S) stores the current state – without any prompt. As long as no working file of your own has been created, the state is kept in the browser and is there again the next time you open it.
Save as (under “Analyses”) creates a file on your drive. This is the only time you are asked where to save. After that, each Save writes silently to the same file.
The first time: Open the file, click “Analyses”, then Save as. From then on, just use the green button.
Autosave: Once an analysis has been saved, the tool automatically saves subsequent changes after a few seconds.
If something goes wrong: the tool continuously keeps an interim state in the browser. If the browser crashes or you close the window by accident, your work is there again the next time you open it.
Note on browsers: writing directly to the file currently works in Chrome and Edge. In Firefox and Safari everything stays saved in the browser – the file itself remains unchanged.