Gemba Kaizen - ENGINEERING.com

More documents

Recommendations

Info

Contents | ix Seiton (Straighten) . . . . . . . . . . . . . . . . . . . . . . . . . 72 Seiso (Scrub) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Seiketsu (Systematize) . . . . . . . . . . . . . . . . . . . . . . . 75 Shitsuke (Standardize) . . . . . . . . . . . . . . . . . . . . . . 75 Introducing 5S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 CHAPTER 6 Muda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Muda of Overproduction . . . . . . . . . . . . . . . . . . . . . . . . 80 Muda of Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Muda of Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Muda of Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Muda of Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Muda of Waiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Muda of Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Muda of Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Categorizing Muda in the Service Sector . . . . . . . . . . . . 87 Muda, Mura, Muri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Mura (Variation) . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Muri (Overburden) . . . . . . . . . . . . . . . . . . . . . . . . . 90 Removing Muda from Public-Sector Organizations . . . 91 CHAPTER 7 The Foundation of the House of Gemba . . . . . . . . 95 A Learning Enterprise . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Suggestion System and Quality Circles . . . . . . . . . . . . . 99 Building Self- Discipline . . . . . . . . . . . . . . . . . . . . . . . . . 100 CHAPTER 8 Visual Management . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Making Problems Visible . . . . . . . . . . . . . . . . . . . . . . . . 103 Staying in Touch with Reality . . . . . . . . . . . . . . . . . . . . 104 Visual Management in the Five Ms (5M) . . . . . . . . . . . 106 Manpower (Operators) . . . . . . . . . . . . . . . . . . . . . 106 Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Visual Management to Manage Complexity . . . . . . . . 108
x | Contents Visual Management with 5S . . . . . . . . . . . . . . . . . . . . . 109 Posting Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Setting Targets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 CHAPTER 9 The Supervisors’ Roles in the Gemba . . . . . . . . . . 113 Training Within Industries. . . . . . . . . . . . . . . . . . . . . . . 113 Managing Input (Manpower, Materials, and Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 A Day in the Life of a Supervisor at Toyota Motor Manufacturing Kentucky. . . . . . . . . . . . . . . . 120 Morning Market (Asaichi) . . . . . . . . . . . . . . . . . . . . . . 126 Best- Line Quality- Assurance Certification . . . . . . . . . 130 Defining Challenges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Pseudo managerial Functions of Supervisors in the Gemba . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 CHAPTER 10 Gemba Managers’ Roles and Accountability . . . 135 Kaizen at Toyota Astra Motor Company Role Manuals at TAM . . . . . . . . . . . . . . . . . . . . . . . . . . 136 TAM Group Leaders’ Responsibilities . . . . . . . . . . . . . 139 TAM Foremen’s Responsibilities . . . . . . . . . . . . . . . . . 140 TAM Supervisors’ Responsibilities . . . . . . . . . . . . . . . . 140 Items That Need to Be Managed in the Gemba . . . . . . 141 Group Leaders’ Daily Schedule of Activities: Examples from the TAM Manual . . . . . . . . . . . 142 Group Leaders’ Activities: Production, Cost, and Quality Examples from the TAM Manual . . . . 143 Foremen’s Activities: Cost -Reduction Examples from the TAM Manual . . . . . . . . . . . . . . . . . . . 145 Supervisors’ Activities: Personnel and Training Examples from the TAM Manual . . . . . . . . . . . 146 Section Managers’ Roles and Accountabilities: Examples from the TAM Manual . . . . . . . . . . . 148 The Conditions Necessary for Successfully Defining Roles and Accountability at TAM . . . . . . . . . . . . . . 148 Staff Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 On- the- Job Training . . . . . . . . . . . . . . . . . . . . . . . 149
Page 2 and 3: Praise for Gemba Kaizen It’s exci
Page 4 and 5: Gemba Kaizen
Page 6 and 7: Gemba Kaizen A Commonsense Approach
Page 8 and 9: CONTENTS Preface . . . . . . . . .
Page 12 and 13: Contents | xi Formal Classroom Trai
Page 14 and 15: PREFACE My two books, Kaizen: The K
Page 16 and 17: ▲ Standardization Preface | xv Ho
Page 18 and 19: ACKNOWLEDGMENTS The first edition o
Page 20 and 21: ABOUT KAIZEN INSTITUTE Founded by M
Page 22 and 23: Gemba Kaizen
Page 24 and 25: CHAPTER ONE An Introduction to Kaiz
Page 26 and 27: Major Kaizen Concepts | 3 ▲ Follo
Page 28 and 29: Act Check Improvement A P C D Figur
Page 30 and 31: Speak with Data Kaizen is a problem
Page 32 and 33: To realize the ideal JIT production
Page 34 and 35: The Ultimate Goal of Kaizen Strateg

Gemba Kaizen - ENGINEERING.com

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?