The house of lean v3.2 kki
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Transcript of The house of lean v3.2 kki
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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
SCRUMSCALABLE
DEVELOPMENT
SMEDUchi-Soto Dandori
·ASAKAY·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 Scheme
WhatIF…
SAFETYMONTHLY MEETING
RCERoot
CauseAnalysis
BPMN2.0PMP
PRODUCTIONMONTHLY MEETING
PRODUCTIONWEEKLY
MEETING
QUALITY
COMITEE
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
Production -Plan
30 Days1
Production -Plan
Weekly
2
Production ControlDAY
3
Forward ControlDAY
4
Machinery/LineProduction
Control
DAY
5
PRODUCTION CONTROL*
7
RAMMPPBureaucracy 6 Wastes
KAIZEN
HEIJUNKA
LEANStart-Up Technics
CIA’sLIST OF
PHOENIX
Moon-shine Concept
TMATherbligs
Motion Analysis
Koichi Kimura Institute. E.L.G. V3.2 © 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/.
Pointing&
Calling
Pointing&
Calling
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CONSTRUCTION OF ENTERPRISE’s 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, 5S, 4R, TPM, OJT, etc. BY ALL.
2. Follow Up in meeting:1. Monthly: Management2. Weekly: Production3. Monthly: Production4. Monthly: Safety5. Monthly: KPIs Targets +
Quality6. Daily: KPIs Targets7. Daily: Graph System
14
DEPARTMENTSALES
PLANNING
SALESPLANNING
MANPOWER,EQUIPMENTPLANNING
& Feed Back
KPIsPlanning
2 3 4
ANNUALDEPARTMENT PLANNING
DEPARTMENTPRODUCTION
PLANNING
6
5
7 8
DEPARTMENTBUDGET
& Feed Back
9
ACTION PLAN
12 13
MAN-MACHINERY POLICYKAIZEN
17
ANNUALDEPARTMENT PLANNING
E.L.G.V3.12015
15 16