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Defects on TA (2.2%)

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Theme:. Name: Company:. Toyota Business Practices (TBP) ■ Problem Solving Flow Chart. The division you belong to: Paint shop in the assembly operations division

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Toyota Business Practices (TBP)

■ Problem Solving Flow Chart

The division you belong to: Paint shop in the assembly operations division

The background of the job: ▼ New paint floor will be established in June 2006, which will increase the production. Currently the incidence of outflow of paint defects has increased.

     ▼ Before establishing the paint floor, we have to decrease the defects without major capital expenditure.

Step 1 Clarify the Problem

Step 2 Break Down the Problem

【Ultimate Goal】

Having 0 painting defect.


By defects categories

Units without defects

Flow out from

Paint shop

Units bought off

By final paint


Units painted &

Baked in top


Units prepared

For painting




Runs & Sags


【Ideal Situation】

(Should be Situation)

2 % or less of vehicles leave assembly hall with paint related defects that require repair.

【Break Down】

By part

Thin paint


Step 3 Target Setting

By car

Tail gate


【Prioritized Problem at point of occurrence】

Defects on HILAY

(8 %)


Paint defects occur

Reduce paint defects




Door interior left


Paint defects leaving assembly hall need to be reduced by 4 %

Defects on



Door interior right


Step 4 Root Cause Analysis

Defects on



Machine is inappropriate

Staff’s performances are poor

Painting materials are poor

Painting methods are ineffective

【Current Situation】

Currently 6 % of vehicles leave assembly hall requiring paint related repairs

Other area


Defects on



Difficult tasks to do

Skills are poor

Staffs do not have capacity to learn

There is a no skill development training for staffs

【The points that you cannot fit in the PS steps,

The researched data that were not apply for breakdown (Incl. Division Points)】


【Root Cause】

. Conduct a training that can improve staffs’ skill development

. Make a poster that reminds staffs not to produce paint defects and put it to a wall

Step 5 Develop Countermeasures