THE HOUSE OF LEAN MANUFACTURING/MANAGEMENT (TPS) V3.4

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