HEIJUNKA ……. .……… ………
CASH-FLOW – COST
SECURITY – LEAD TIME – QUALITY
JIT JIDOKA
STANDARDIZATION STABILIZATION
ENTERPRISE OPERATING SYSTEM (e-OS**)
LEAN MANUFACTURING/MANAGEMENT (TPS)
TEAM
WORK
(WASTES)
MUDA
PDCACycle
FMEAPOKA
YOKEQFD
A3
QRQCQRKAQ-Chart
5
WHYS
ISHI-
KAWA8D
PSP
· IT’S &
· IT’S NOT· IN/OUT BOX
ONE
POINT
LESSON
BRAINSTORM
…
6σDMAIC
KJMETHOD
MINDMAP
POKERESTIMATION
ANDONBOARD
PM
TAKT
Time
TPM
ONEPIECE
FLOW
ANDON
CYCLE
Time
JUNJIINSPECTION
NEXT
5SPika-Pika
PUSH
PULL
ICPTCPPCP
VSM
SCRUM
SCALABLEDEVELOPMENT
SMEDUchi-Soto
Dandori
·ASAKAYDayly-Huddle
·YUICHI
POP
4RRULES
3AAllocationAmountArticle
PTSSProcess Time
Study Sheet
QCCJUNDATE
JUNBIKI
TIMWOOD
Production
7 Wastes
KAMI-
SHIBAICARDS &
TABLE
MIZU-
SUMASHI
DandoriMan
KAIZEN-
BLITZKAIKAKU
Shijonkapolyvalence
SoifukuIdea from
empowerment
5ZEROstheory
KATAZUKE
AKAFUDA
SPS /
KIT
6-Hats
Disney
LTLTEfficiency
LTStandard
KANBAN SEIRYUKA(Cells & Machinery easy to relocate)
PRODUCTS
PRODUCTION
5W+H
(+2H)
INVENTORY SALESYAMA-
KUZUSHIDAILY
MURA
MURI
(Safety 1st)
ANZEN DAIICHI
PQCDiagram
KaizenOutOfLine
3GGemba
GenbutsuGenjitsu
*VISUAL CONTROL
DAILY TARGET
DAYLY CONTROL
PRODUC-
TION
/ACTION
PLAN
KPI &
HOSHIN
KANRI
BMCBusinessModelCanvas
AS IS
TO BE
KAIZEN PROGRESS
CHART
PPMPOTENTIAL
PROBLEMS
MAP
FOCUS
ON
PEOPLE
INVOL-
VEMENT
BY ALL
LONG
TERM
VISION
KPI
DAILY
MEETING
KPI & QMONTHLY
MEETING
FAULT
TREE ANALYSIS
PARETO &
CorrelationANALYSIS
RCERootCause
Analysis
TQM
ISO…
Suggestion
Scheme
QCC
What
IF…
SAFETYMONTHLY
MEETING
RCERootCause
Analysis
BPMN
2.0PMP
PRODUCTION
MONTHLY
MEETING
PRODUCTION
WEEKLY
MEETING
QUALITY
COMITEESAFETYCOMITEE
Production
COMITEE
DESING
THINKING
TOOLS…
MVPMinimumProductViable
MGMT.
COMETEE
MGMT.MONTHLY
MEETING
3SCS, ES, SS
KAIZENCOMITEE
1
2
3
45
1
2
3
45 6
CHAKU
CHAKU
YAMA-
ZUMI
KARA
KURI
LCALow Cost
Automation
3PProductionPreparation
Process
OJT/TWI
Hancho
CELL
LCALive Cycle
Assessment
Burn-
down
Chart
Ji KouteiKanketsu
ILUOMatrix
(STM)
PCTProcess
Capability Table
SWCTStandardized
Work Combi-
nation Table
SOSStandardized
Operation Sheet
PABProduction
Analysis Board
STMSkills Training
Matrix
ILUO Matrix
OBCOperator Balance
Chart
SWCStandardized
Work Chart
KANBAN
BOARDs
1 2 3 4 5 6 7 8
Handan-
kijun
Process
Spaghetti
Diagram
SIPOCDiagram
Production
Plan
30 Days
1
Production
Plan
Weekly
2
Production
Control
DAY
3
Forward
Control
DAY
4
Machinery/Line
Production
Control
DAY
5
PRODUCTION
CONTROL*
7
RAMMPP
Bureaucracy
6 Wastes
KAIZEN
HEIJUNKA
LEAN
Start-Up
Technics
CIA’s
LIST OF
PHOENIX
Moon-shine
Concept
TMATherbligs
Motion Analysis
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-nd/4.0/. (KKI-ELG 2016 ©)
Pointing&
Calling
Pointing&
Calling
The
Trimming
Technique
Ø
VA/VE
Koichi Kimura Institute. V3.4 © 2016
www.kokinstitute.com
THE ENTERPRISE OPERATING SYSTEM (e-OS**)
COMPANY POLICY
HOSHIN
KANRI
PLANNING
FINANCIALs
PLANING &
COST /u
KPIs &
TARGET
PLANNING
ACTION PLAN
FOR
ACHIEVING
DEPARMENT
BUDGET
DEPARTMENT
BUDGET
PRODUCTION
PLANMONTH,
WEEK, DAY
1
DEPARTMENT POLICY
10
DAILY
FOLLOWUP
& GRAPH
SYSTEM
ACT OF
PRODUCTION
Throughout
PRODUNTION
PLAN
DAILY
TARGET &
VISUAL
CONTROL
11
1. QCC + Suggestion Scheme: By ALL
2. Follow-Up in meetings:Monthly: ManagementMonthly: ProductionMonthly: KAIZEN + SafetyMonthly: KPIs Targets + QualityWeekly: ProductionWeekly: QCCsDaily: KPIs Targets (ASAKAY)Daily: Graph SystemDaily: TrainingJIT: QRQC/QRQA (PDCA + Standardization)
3. Every Lean Tools: 5S, 4R, TPM, etc.
14
DEPARTMENT
SALES
PLANNING
SALES
PLANNING
MANPOWER &
EQUIPMENT
PLANNING
& Feed Back
KPIs
Planning
2 3 4
ANNUAL
DEPARTMENT
PLANNING
DEPARTMENT
PRODUCTION
PLANNING
6
5
7 8
DEPARTMENT
BUDGET
& Feed Back
9
ACTION
PLAN
12 13
LINE / MAN-MACHINERY POLICY KAIZEN17
ANNUAL
DEPARTMENT
PLANNING
15 16
Koichi Kimura Institute. V3.4 - ELG © 2016
www.kokinstitute.com
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by-nc-nd/4.0/. (KKI-ELG 2016 ©)
PDCA + Standardization
PDCA + Standardization
12
6
ACHIEVING THE BASIC CONDITION FOR KAIZEN & LEAN-TOOLS APPLICATION