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
