The house of lean v3.2 kki

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

http://www.kokinstitute.com/

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

The house of lean v3.2 kki

Engineering

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