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