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HEIJUNKA ……. .……… ………
CASH-FLOW – COSTSECURITY – LEAD TIME – QUALITY
JIT JIDOKA
STANDARDIZATION STABILIZATION
ENTERPRISE OPERATING SYSTEM (e-OS**)
LEAN MANUFACTURING/MANAGEMENT (TPS)
TEAM WORK
(WASTES)
MUDA
PDCACycle
FMEAPOKAYOKE
QFD
A3
QRQCQRKAQ-Chart
5WHYS
ISHI-KAWA
8DPSP
· IT’S &· IT’S NOT· IN/OUT BOX
ONEPOINT
LESSON
BRAINSTORM
…
6σDMAIC
KJMETHOD
MINDMAP
POKERESTIMATION
ANDONBOARD
PM
TAKTTime
TPM
ONEPIECEFLOW
ANDON
CYCLETime
JUNJIINSPECTION
NEXT
5SPika-Pika
PUSHPULL
ICPTCPPCP
VSM
SCRUMSCALABLEDEVELOPMENT
SMEDUchi-Soto Dandori
·ASAKAYDayly-Huddle·YUICHI
POP
4RRULES
3AAllocationAmountArticle
PTSSProcess TimeStudy Sheet
QCCJUNDATE
JUNBIKI
TIMWOODProduction7 Wastes
KAMI-SHIBAI
CARDS & TABLE
MIZU-SUMASHIDandoriMan
KAIZEN-BLITZ
KAIKAKU
Shijonkapolyvalence
SoifukuIdea from
empowerment
5ZEROstheory
KATAZUKEAKAFUDA
SPS /KIT
6-HatsDisney
LTLTEfficiency
LTStandard
KANBAN SEIRYUKA(Cells & Machinery easy to relocate)
PRODUCTS
PRODUCTION
5W+H(+2H)
INVENTORY SALESYAMA-
KUZUSHIDAILY
MURAMURI
(Safety 1st)
ANZEN DAIICHI
PQCDiagram
KaizenOutOfLine
3GGemba
GenbutsuGenjitsu
*VISUAL CONTROL
DAILY TARGET
DAYLY CONTROL
PRODUC-TION
/ACTION PLAN
KPI & HOSHINKANRI
BMCBusinessModelCanvas
AS ISTO BE
KAIZEN PROGRESS
CHART
PPMPOTENTIAL PROBLEMS
MAP
FOCUS ON
PEOPLE
INVOL-VEMENT BY ALL
LONG TERM
VISION
KPIDAILY
MEETING
KPI & QMONTHLYMEETING
FAULT TREE
ANALYSIS
PARETO &CorrelationANALYSIS
RCERootCause
Analysis
TQMISO…
Suggestion SchemeQCC
WhatIF…
SAFETYMONTHLY MEETING
RCERootCause
Analysis
BPMN2.0PMP
PRODUCTIONMONTHLY MEETING
PRODUCTIONWEEKLY
MEETING
QUALITYCOMITEE
SAFETYCOMITEE
ProductionCOMITEE
DESING THINKING TOOLS…
MVPMinimumProductViable
MGMT.COMETEE
MGMT.MONTHLY MEETING
3SCS, ES, SS
KAIZENCOMITEE
1
2
3
45
1
2
3
45 6
CHAKUCHAKU
YAMA-ZUMI
KARAKURI
LCALow Cost
Automation
3PProductionPreparation
Process
OJT/TWIHancho
CELL
LCALive CycleAssessment
Burn-down Chart
Ji KouteiKanketsu
ILUOMatrix(STM)
PCTProcess
Capability Table
SWCTStandardized Work Combi-nation Table
SOSStandardized
Operation Sheet
PABProduction
Analysis Board
STMSkills Training
MatrixILUO Matrix
OBCOperator Balance
Chart
SWCStandardized Work Chart
KANBANBOARDs
1 2 3 4 5 6 7 8
Handan-kijun
Process
Spaghetti Diagram
SIPOCDiagram
ProductionPlan
30 Days1
ProductionPlan
Weekly2
Production ControlDAY
3
Forward ControlDAY
4
Machinery/LineProduction ControlDAY
5
PRODUCTION CONTROL*
7
RAMMPPBureaucracy 6 Wastes
KAIZEN
HEIJUNKA
LEANStart-Up Technics
CIA’sLIST 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
TheTrimmingTechnique
Ø
VA/VE
Koichi Kimura Institute. V3.4 © 2016www.kokinstitute.com
Koichi Kimura Institute
THE ENTERPRISE OPERATING SYSTEM (e-OS**)
COMPANY POLICY
HOSHIN KANRI
PLANNING
FINANCIALs PLANING &
COST /u
KPIs & TARGET
PLANNING
ACTION PLANFOR
ACHIEVING DEPARMENT
BUDGET
DEPARTMENTBUDGET
PRODUCTION PLAN
MONTH, WEEK, DAY
1
DEPARTMENT POLICY
10
DAILYFOLLOWUP
& GRAPH SYSTEM
ACT OF PRODUCTION Throughout
PRODUNTION PLAN
DAILY TARGET &
VISUAL CONTROL
11
1. QCC + Suggestion Scheme: By ALL2. 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
DEPARTMENTSALES
PLANNING
SALESPLANNING
MANPOWER &EQUIPMENTPLANNING
& Feed Back
KPIsPlanning
2 3 4
ANNUALDEPARTMENT PLANNING
DEPARTMENTPRODUCTION
PLANNING
6
5
7 8
DEPARTMENTBUDGET
& Feed Back9
ACTION PLAN
12 13
LINE / MAN-MACHINERY POLICY KAIZEN17
ANNUALDEPARTMENT PLANNING
15 16
Koichi Kimura Institute. V3.4 - ELG © 2016www.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
Koichi Kimura Institute