The House of Lean v3.4 Koichi Kimura Institute

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HEIJUNKA . . CASH-FLOW COSTSECURITY LEAD TIME QUALITY

JITJIDOKA

STANDARDIZATIONSTABILIZATION

ENTERPRISE OPERATING SYSTEM (e-OS**) LEAN MANUFACTURING/MANAGEMENT (TPS)TEAM WORK(WASTES)MUDAPDCACycleFMEAPOKAYOKEQFDA3QRQCQRKAQ-Chart5WHYSISHI-KAWA8DPSP ITS & ITS NOT IN/OUT BOXONEPOINT LESSONBRAINSTORM6DMAICKJMETHOD MINDMAPPOKERESTIMATIONANDONBOARDPMTAKTTimeTPMONEPIECEFLOWANDONCYCLETimeJUNJIINSPECTION NEXT5SPika-PikaPUSHPULLICPTCPPCPVSMSCRUM

SCALABLEDEVELOPMENT

SMEDUchi-Soto DandoriASAKAYDayly-HuddleYUICHIPOP4RRULES3AAllocationAmountArticlePTSSProcess TimeStudy SheetQCCJUNDATEJUNBIKITIMWOODProduction7 WastesKAMI-SHIBAICARDS & TABLEMIZU-SUMASHIDandoriManKAIZEN-BLITZKAIKAKUShijonkapolyvalenceSoifukuIdea from empowerment5ZEROstheoryKATAZUKEAKAFUDASPS /KIT6-HatsDisneyLTLTEfficiencyLTStandardKANBANSEIRYUKA(Cells & Machinery easy to relocate)PRODUCTS

PRODUCTION5W+H(+2H)INVENTORYSALESYAMA-KUZUSHIDAILYMURAMURI (Safety 1st) ANZEN DAIICHIPQCDiagramKaizenOutOfLine3GGembaGenbutsuGenjitsu*VISUAL CONTROLDAILY TARGETDAYLY CONTROLPRODUC-TION /ACTION PLANKPI & HOSHINKANRIBMCBusinessModelCanvasAS ISTO BEKAIZEN PROGRESSCHARTPPMPOTENTIAL PROBLEMS MAPFOCUS ON PEOPLEINVOL-VEMENT BY ALLLONG TERM VISIONKPIDAILY MEETINGKPI & QMONTHLYMEETINGFAULT TREE ANALYSISPARETO &CorrelationANALYSISRCERootCauseAnalysisTQMISOSuggestion SchemeQCCWhatIFSAFETYMONTHLY MEETINGRCERootCauseAnalysisBPMN2.0PMPPRODUCTIONMONTHLY MEETINGPRODUCTIONWEEKLY MEETINGQUALITYCOMITEESAFETYCOMITEEProductionCOMITEE DESING THINKING TOOLSMVPMinimumProductViableMGMT.COMETEEMGMT.MONTHLY MEETING3SCS, ES, SSKAIZENCOMITEE12345123456CHAKUCHAKUYAMA-ZUMIKARAKURILCALow CostAutomation3PProductionPreparationProcessOJT/TWIHanchoCELLLCALive CycleAssessmentBurn-down ChartJi KouteiKanketsuILUOMatrix(STM)PCTProcess Capability TableSWCTStandardized Work Combi-nation TableSOSStandardized Operation SheetPABProduction Analysis BoardSTMSkills Training MatrixILUO MatrixOBCOperator BalanceChartSWCStandardized Work ChartKANBANBOARDs12345678Handan-kijunProcessSpaghetti DiagramSIPOCDiagramProductionPlan30 Days1ProductionPlanWeekly2Production ControlDAY3Forward ControlDAY4Machinery/LineProduction ControlDAY5PRODUCTION CONTROL*7RAMMPPBureaucracy 6 WastesKAIZENHEIJUNKALEANStart-Up TechnicsCIAsLIST OF PHOENIXMoon-shine ConceptTMATherbligs 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&CallingPointing&CallingTheTrimmingTechniqueVA/VEKoichi Kimura Institute. V3.4 2016www.kokinstitute.com

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THE ENTERPRISE OPERATING SYSTEM (e-OS**)COMPANY POLICYHOSHIN KANRI PLANNINGFINANCIALs PLANING & COST /u

KPIs & TARGETPLANNINGACTION PLANFOR ACHIEVING DEPARMENT BUDGETDEPARTMENTBUDGETPRODUCTION PLANMONTH, WEEK, DAY1DEPARTMENT POLICY10

DAILYFOLLOWUP& GRAPH SYSTEM

ACT OF PRODUCTION Throughout PRODUNTION PLANDAILY TARGET & VISUAL CONTROL11QCC + Suggestion Scheme: By ALLFollow-Up in meetings:Monthly: ManagementMonthly: ProductionMonthly: KAIZEN + SafetyMonthly:KPIs Targets + QualityWeekly: ProductionWeekly: QCCsDaily:KPIs Targets (ASAKAY)Daily: Graph SystemDaily:TrainingJIT: QRQC/QRQA (PDCA + Standardization)Every Lean Tools: 5S, 4R, TPM, etc. 14

DEPARTMENTSALESPLANNING

SALESPLANNING

MANPOWER &EQUIPMENTPLANNING& Feed Back

KPIsPlanning234ANNUALDEPARTMENT PLANNINGDEPARTMENTPRODUCTION PLANNING6578DEPARTMENTBUDGET& Feed Back

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ACTION PLAN1213LINE / MAN-MACHINERY POLICYKAIZEN17ANNUALDEPARTMENT PLANNING

1516Koichi 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 + StandardizationPDCA + Standardization126

ACHIEVING THE BASIC CONDITION FOR KAIZEN & LEAN-TOOLS APPLICATION

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