HEIJUNKA ……. .……… ………

CASH-FLOW – COSTSECURITY – LEAD TIME – QUALITY

JIT JIDOKA

STANDARDIZATION STABILIZATION

FACTORY MANAGEMENT

LEAN MANUFACTURING/MANAGEMENT (TPS)

TEAM WORK

(WASTES)

MUDA

E.L.G.V2.22015

PDCACycle

FMEA

POKAYOKE

QFD A3QRQCQRKAQ-Chart

5WHYS

ISHI-KAWA

8D

· IT’S &· IT’S NOT· IN/OUT BOX

ONEPOINT

LESSON

BRAINSTORM

6σKJ

METHOD

MINDMAP

POKERESTIMATION

ANDONBOARD

PM

TACKTime

TPM

ONEPIECE

FLOWANDON

CYCLETime

JUNJIINSPECTION

NEXT

5SPikaPika

PUSH

PULL

ICPTCPPCP

VSM

SCRUMSCALABLE

DEVELOPMENT

SMEDUchi & Soto

Dandori

·ASAKAY·YUICHI

POP

4RRULES

3AAllocationAmountArticle

PTSSProcess

Time Study

Sheet

QCCJUNDATE

JUNBIKI

TIMWOOD

Production

7 Wastes

KAMI-SHIBAICARDS &

TABLE

MIZU-SUMASHIDandoriMan

KAIZEN-BLITZ

KAIKAKUShijonkapolyvalence

SoifukuIdea from

empowerment

5ZEROstheory

KATAZUKEAKAFUDA

SPS /KIT

6-HatsDisney

LTLTEfficiency

LTStandard

KANBAN SEIRYUNKA(Cells & Machinery easy to relocate)

PRODUCTS

5 W+H

INVENTORY SALESYAMA-

KUZUSHIDAILY

MURA

MURI

(Safety 1st)

ANZEN DAIICHI

PQCDiagram

KaizenOutOfLine

3GGemba

GenbutsuGenjitsu

*VISUAL CONTROL

DAILY TARGET

DAYLY CONTROL

PRODUC-TION

PLAN

KPI & HOSHINKANRI

BMCBusiness

ModelCanvas

AS ISTO BE

KAIZEN PROGRESS

CHART

PPMPOTENTIAL

PROBLEMS MAP

FOCUS ON

PEOPLE

INVOL-VEMENT BY ALL

LONG TERM VISION

KPIDAILY

MEETING

KPI & QMONTHLY

MEETING

FAULT TREE

ANALYSIS

PARETO ANALYSIS

RCERoot

CauseAnalysis

TQM…

Suggestion

SchemeWhatIF…

SAFETYMONTHLY

MEETING

RCERoot

CauseAnalysis

BPMN2.0

PMPPRODUCTION

MONTHLY

MEETING

PRODUCTION

WEEKLY

MEETING

QUALITYCOMITEE

SAFETYCOMITEE

Production

COMITEE

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/TWI

Hancho

CELL

LCALive CycleAssessment

KaizenPS

Table

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

WorkChart

KANBANBOARDs

1 2 3 4 5 6 7 8

Handan-kijun

Process

Spaghetti

Diagram

SIPOCDiagram

Production

-Plan30 Days

1

Production

-PlanWeekly

2

Production Control

DAY

3

Forward Control

DAY

4

Machinery/Line

Production Control

DAY

5

PRODUCTION

CONTROL*

7

RAMMPPBureaucracy

6 Wastes

KAIZEN

HEIJUNKA

CONSTRUCTION OF FACTORY MANAGEMENT

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.V2.02015