Toyota's Tricks of the Trade

In addition to various areas of co ft savings, Toyota manufacturing widely seen as being technically superior to its American counterparts.  The vaunted Toyota Production System is often replicated elsewhere.  But it's not all robots and precision engineering.  The system has some pretty low-tech features to keep it running smoothly.

A "shadowboard" is a common method in the Toyota Production System. It is a "5S" method where an outline or solid "shadow" is drawn behind where a tool would go on a board, bench, or table. With the shadowboard, it is easy to tell where tools go and when something is missing (a key element of visual management).

Now, via the above link here's a picture of a shadowboard used for tools.

Notice,  the screwdriver-like instrument is just an outline, so a factory worker could quickly realize that the tool was missing from its proper place before leaving his or her workstation.

It's a low tech technique, but it works.  Or, you could spend millions installing a new RFID system, and attaching a tag to each tool.  Your call.

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