Kamishibai 紙芝居Created by Todd McCann

Contents:>Shallow instructions for use>Example of application

A Quote from Taiichi Ohno

“ Where there is NO Standardthere can be NO KAIZEN”

We Serve the GEMBA We Teach Leaders to “Learn to See” and “Serve the Gemba”

Focus and Aim of Kamishibai ProcessEstablish standard inspection discipline and method focused on a specific area/zone using direct observation combined with detailed knowledge of formal standards in area, with an aim to ensure standard is being achieved, sustained and improved.Key Objectives:

>Establish standard inspection method for detection of deficiencies /abnormalities to a known standard

>Shared responsibility and commitment for the benefit of others not the “inspector”

>Expose abnormalities /deficiencies to established standard condition

>Elimination of Muda, Mura and Muri

>Prompt and timely correction of root cause of deficiency / abnormality

>Create an environment of Healthy and Positive Challenge to current condition

and enable a “soon certain and positive” feedback loop to immediately address abnormalities in current condition

>Create environment and condition of improvement (KAIZEN spirit/thinking) in the inspector, individuals and

processes in the area being inspected>Create High Touch, No Tech, Low Tech environment for tracking corrective actions to address abnormalityFoundational Skills required

>Detailed working knowledge , root understanding of the standard to be inspected, ability to objectively know difference of Good to a No Good condition to standard being inspected>Servant Leadership, respect, humility>Direct observation>Root Cause thinking and analysis>Countermeasure production>7 Wastes>Muda Mura Muri>PDCA>KAIZEN Spirit practices and activities>Eyes for Warusa Kagen> Shitsuke> Challenge Spirit

Created By: Todd McCannDate created: 2-10-2011Subject: Kamishibai Process to supportManagement Observation Program and Leadership Safety Audit

Card(s) >One side RED >One side GREEN >Both sides contain same

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Standard Work Instructions

Each card contains Standard work instructions to perform an inspection at a prescribed location/area at the Gemba. Instruction describes the “WHAT” is to be performed in the inspection (GOOD <> NO GOOD criteria must be specific, clear and concise) No Muri No Confusion

The instructions are developed from the known Standard Conditions that must be met at the location/areas where the inspection will be conducted

KAMISHIBAI POST

>A location where inspection cards are visually displayed for all to see , along with the inspection results

>The standard mechanism created to organize inspection cards for presentation to the inspectors and those who are willing to learn to inspect status of current state condition

> Minimum requirements of Post:A board constructed to enable visible and visual workflow for use of postClear and concise visual controlsContainers for cards (alternatives exist to eliminate need for containers)Standard Work Instructions for applicationStandard Schedule for InspectionsDeficiency /Abnormality corrective action trackingCards that are randomly selected for use during inspectionTraining to support users of board

Example: Kamishibai Post

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Name of Zone/Target Area of Inspection Focus Deficiency / Abnormality tracking

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Problem / Abnormality Description

Root Cause Proposed Countermeasure

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2 X No 8x11 paper for copier in area when needed

No standard replenish system exists

5 S area + set up KANBAN process for replenishment

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Key Elements of Kamishibai

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KamishibaiStandard Work

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KamishibaiStandard Schedule

Outgoing“To be

Completed”

Incoming“Completed”

Standard Schedule

A “Level Loaded” schedule to perform inspections is established The schedule creates the condition of “Shared Responsibility and Commitment” and Balanced Loading over time3 Components evenly balanced and loaded > WHO will conduct inspections> WHEN Calendar time (no batch)> WHERE Location/area of inspection

Key Elements of Kamishibai

Closed Loop Thinking “PDCA”Kamishibai process MUST deliberately create a positive feedback loop so problems /abnormalities that are identified “are addressed” in a timely manner for the benefit of others.

Key Point: Positive Feedback loop that is CLOSED to prevent recurrence of abnormality.

Discipline to Sustain (Shitsuke)

Discipline of the users of the process of Kamishibai is a must to prevent backsliding to previous condition when there was no check and inspection for standard.

Key Point: Earn your Honor through Discipline

CULTURE of RESPECT The organization attempting to apply KAMISHIBAI MUST POSSESS a Healthy “WHY” culture NOT a “WHO” culture. No BLAMING > think process not responsibility > be a servant to others in need for the benefit of others. “Just Culture”

Key Point: Inspection is not for your benefit it is for the benefit of others with no Blame.

Spirit of Humility and Modesty

Kamishibai users must have a value to be aware

that they do not know everything about everything. Be humble to the condition your are observing and the people operating in the condition when performing inspection. Focus on improvement.

Key Point: Please be aware of your ignorance

KAIZEN SpiritKamishibai users must have a value that enables them to inspect an area

with improvement in mind, not just change.

Key Point: Improvement mindset, not just to change for sake of change . Must be a true benefit, not an apparent benefit.

Eye’s for Seeing AbnormalityWarusa Kagen

“Condition of Badness”Kamishibai

users must have the skill of detecting small abnormalities in the current condition through direct observation

Key Point: The ability to See abnormalities and deficiencies

悪さかげん

Mindsets & BehaviorsFoundation Skills and Conditions

Challenge SpiritAll users of Kamishibai must understand and demonstrate components of challenge spirit. 1. Perform inspection with open

mind and go see area to learn FIRST about what is happening in the condition with no pre-conceived images of what inspector will observe.

2. When inspection is over the observer should deliberately create “internal struggle” to improve the condition, contradiction should be produced in the mind of inspector during and after the inspection. Share findings with others Learning by sharing takes place.

Key Point: Internal Struggle focused on What SHOULD be happening not what IS happening in the current condition should occur in inspector

Visual Management for Outputs of Inspection

Creates a public record of findings, root cause, and countermeasures (corrective actions) to be installed in location of inspection.

Kamishibai (紙芝居 )

Created By: Todd McCannDate created: 2-10-2011Subject: Kamishibai Process to supportManagement Observation Program and Leadership Safety Audit

Alternative Layouts and Workflows for Kamishibai PostAlternative 1Ex: Control Room Observations > Operational Focus > Management Observation Program / Leadership Safety Audit

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Description of Area or Zone to be audited (HERE)

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Step 3>Participant offers positive feedback to those observed, area owner, process owner immediately after observation.>Offers coaching when necessary>Participant then returns to Kamishibai Post

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Description of Area or Zone to be audited (HERE)

Step 4>Participant places completed card in INCOMING Completed container

Incoming“Completed”

Step 5>Participant creates Condition Report for findings of observation/audit and any coaching that was provided, closes CR.REPEAT…Until Post contains 1 card (#5 Friday)>Execute Step 6

Step 6Kamishibai Post

End of week Re-Loading>The LAST card (Friday #5) is the signal for post reload/restore.>Participant who selects last card is responsible for reload>All Cards in INCOMING COMPLETED box are shuffled and placed at random to restore the board to starting condition.

RESTORE KAMISHIBAI POST to STARTING CONDITION

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Description of Area or Zone to be audited (HERE)

Kamishibai (紙芝居 )

Reflect on What you learned during the audit

What will you do to support improvement?

Step 1>Participant removes card in order 1-2-3..>Reviews Criteria>Prepares for observation

Step 2>Participant travels to location where observation will occur>Performs observation to criteria on card>Observer audits area, process to a known standard completes card and takes additional notes when required

Look for what SHOULD be occurring NOT what IS occurringWhat obstacles / barriersare present to meeting standard condition and to improving current condition(Be mindful that Abnormalities may be hidden from your view during observation)

Candidly dialoguewith others regarding results of observation/audit Discuss current obstacles and barriers to meeting standard and potential ideas of and for improvement

Starting ConditionWHO: 5 participants use this postEach participant has committed to performing 1 audit per weekWHEN: Weekly cycle displayed 5 days Total audits = 5 per weekWHERE and WHAT are represented on the cardHOW: GO SEE the area and perform audit

STARTING ConditionAt beginning of audit cycle all cards in post start with RED side out indicatingINCOMPLETE

Created By: Todd McCannDate created: 2-10-2011Subject: Kamishibai Process to supportManagement Observation Program and Leadership Safety Audit

Alternative Layouts and Workflows for Kamishibai PostAlternative 2Ex: Control Room Observations > Operational Focus > Management Observation Program / Leadership Safety Audit

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Step 1>Participant removes card in order 1-2-3..>Reviews Criteria>Prepares for observation

Step 2>Participant travels to location where observation will occur>Performs observation to criteria on card>Observer audits area, process to a known standard completes card and takes additional notes when required

Step 3>Participant offers positive feedback to those observed, area owner, process owner immediately after observation.>Offers positive coaching when necessary>Participant then returns to Kamishibai Post

Step 4>Participant places completed card back into Space and Day slot from which it was removed>Participant places RED side out indicating deficiencies/abnormalities discovered during audit

OR> Participant places GREEN side out indicating NO deficiencies/abnormalities discovered during audit

Step 5>Participant creates Condition Report for findings of observation/audit and any coaching that was provided, closes CR.REPEAT…Until Post contains 1 card (#5 Friday)>Execute Step 6

Step 6Kamishibai Post

End of week Re-Loading>The LAST card (Friday #5) is the signal for post reload/restore.>Participant who selects last card is responsible for reload>All Cards on post are removed and shuffled and placed at random to restore the board to starting condition.

RESTORE KAMISHIBAI POST to STARTING CONDITION

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Description of Area or Zone to be audited (HERE)

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SPECIAL NOTE (Visual Management)Using a full view visual board alternative enablesVisual trending of condition to General Public“Keep Problems Visible, do not hide in computer”More GREEN = GOODMore RED = NO GOOD

Kamishibai (紙芝居 )

Reflect on What you learned during the audit

What will you do to support improvement?

Starting ConditionWHO: 5 participants use this postEach participant has committed to performing 1 audit per weekWHEN: Weekly cycle displayed 5 days Total audits = 5 per weekWHERE and WHAT are represented on the cardHOW: GO SEE the area and perform audit

STARTING ConditionAt beginning of audit cycle all cards in post start with RED side out indicatingINCOMPLETE

Look for what SHOULD be occurring NOT what IS occurringWhat obstacles / barriersare present to meeting standard condition and to improving current condition(Be mindful that Abnormalities may be hidden from your view during observation)

Candidly dialoguewith others regarding results of observation/audit Discuss current obstacles and barriers to meeting standard and potential ideas of and for improvement