Lean

1. 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
PDCA
Cycle
FMEAPOKA
YOKE
QFD
A3
QRQC
QRKA
Q-Chart
5
WHYS
ISHI-
KAWA
8D
PSP
· IT’S &
· IT’S NOT
· IN/OUT BOX
ONE
POINT
LESSON
BRAIN
STORM
…
6σ
DMAIC
KJ
METHOD
MINDMAP
POKER
ESTIMATION
ANDON
BOARD
PM
TAKT
Time
TPM
ONE
PIECE
FLOW
ANDON
CYCLE
Time
JUNJI
INSPECTION
NEXT
5S
Pika-Pika
PUSH
PULL
ICP
TCP
PCP
VSM
SCRUM
SCALABLE
DEVELOPMENT
SMED
Uchi-Soto
Dandori
·ASAKAY
Dayly-Huddle
·YUICHI
POP
4R
RULES
3A
Allocation
Amount
Article
PTSS
Process Time
Study Sheet
QCCJUNDATE
JUNBIKI
TIMWOOD
Production
7 Wastes
KAMI-
SHIBAI
CARDS &
TABLE
MIZU-
SUMASHI
DandoriMan
KAIZEN-
BLITZ
KAIKAKU
Shijonka
polyvalence
Soifuku
Idea from
empowerment
5ZEROs
theory
KATAZUKE
AKAFUDA
SPS /
KIT
6-Hats
Disney
LT
LTEfficiency
LTStandard
KANBAN SEIRYUKA
(Cells & Machinery easy to relocate)
PRODUCTS
PRODUCTION
5W+H
(+2H)
INVENTORY SALES
YAMA-
KUZUSHI
DAILY
MURA
MURI
(Safety 1st)
ANZEN DAIICHI
PQC
Diagram
Kaizen
OutOfLine
3G
Gemba
Genbutsu
Genjitsu
*VISUAL
CONTROL
DAILY
TARGET
DAYLY
CONTROL
PRODUC-
TION
/ACTION
PLAN
KPI &
HOSHIN
KANRI
BMC
Business
Model
Canvas
AS IS
TO BE
KAIZEN
PROGRESS
CHART
PPM
POTENTIAL
PROBLEMS
MAP
FOCUS
ON
PEOPLE
INVOL-
VEMENT
BY ALL
LONG
TERM
VISION
KPI
DAILY
MEETING
KPI & Q
MONTHLY
MEETING
FAULT
TREE
ANALYSIS
PARETO &
Correlation
ANALYSIS
RCE
Root
Cause
Analysis
TQM
ISO…
Suggestion
Scheme
QCC
What
IF…
SAFETY
MONTHLY
MEETING
RCE
Root
Cause
Analysis
BPMN
2.0
PMP
PRODUCTION
MONTHLY
MEETING
PRODUCTION
WEEKLY
MEETING
QUALITY
COMITEE
SAFETY
COMITEE
Production
COMITEE
DESING
THINKING
TOOLS…
MVP
Minimum
Product
Viable
MGMT.
COMETEE
MGMT.
MONTHLY
MEETING
3S
CS, ES, SS
KAIZEN
COMITEE
1
2
3
45
1
2
3
45 6
CHAKU
CHAKU
YAMA-
ZUMI
KARA
KURI
LCA
Low Cost
Automation
3P
Production
Preparation
Process
OJT/TWI
Hancho
CELL
LCA
Live Cycle
Assessment
Burn-
down
Chart
Ji Koutei
Kanketsu
ILUO
Matrix
(STM)
PCT
Process
Capability Table
SWCT
Standardized
Work Combi-
nation Table
SOS
Standardized
Operation Sheet
PAB
Production
Analysis Board
STM
Skills Training
Matrix
ILUO Matrix
OBC
Operator Balance
Chart
SWC
Standardized
Work Chart
KANBAN
BOARDs
1 2 3 4 5 6 7 8
Handan-
kijun
Process
Spaghetti
Diagram
SIPOC
Diagram
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
TMA
Therbligs
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

2. 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
PLAN
MONTH,
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: Management
Monthly: Production
Monthly: KAIZEN + Safety
Monthly: KPIs Targets + Quality
Weekly: Production
Weekly: QCCs
Daily: KPIs Targets (ASAKAY)
Daily: Graph System
Daily: Training
JIT: 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