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Kamishiba process and general training instructions created bytodd mccann[3]
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Kamishiba process and general training instructions created bytodd mccann[3]

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  • 1. Contents: >Shallow instructions for use >Example of application Kamishibai 紙芝居 Created by Todd McCann A Quote from Taiichi Ohno “ Where there is NO Standard there can be NO KAIZEN” We Serve the GEMBAWe Teach Leaders to “Learn to See” and “Serve the Gemba”
  • 2. Created By: Todd McCannFocus and Aim of Kamishibai Process Date created: 2-10-2011 Key Elements of Kamishibai Key Elements of Kamishibai Kamishibai (紙芝居) Subject: Kamishibai Process to supportEstablish standard inspection discipline and Management Observation Programmethod focused on a specific area/zone Mindsets & Behaviors and Leadership Safety Audit Materials requiredusing direct observation combined with Foundation Skills and Conditionsdetailed knowledge of formal standards inarea, with an aim to ensure standard isbeing achieved, sustained and improved. KAMISHIBAI POST CULTURE of RESPECT Challenge SpiritKey Objectives: All users of Kamishibai must The organization attempting to >A location where inspection cards are visually displayed for all to see , along with the inspection>Establish standard inspection method for apply KAMISHIBAI MUST understand and demonstrate results POSSESS a Healthy “WHY” components of challenge spirit. detection of deficiencies /abnormalities culture NOT a “WHO” culture. 1. Perform inspection with open >The standard mechanism created to organize inspection cards for presentation to the to a known standard No BLAMING > think process not mind and go see area to learn inspectors and those who are willing to learn to inspect status of current state condition>Shared responsibility and commitment responsibility > be a servant to FIRST about what is happening Flip over others in need for the benefit of in the condition with no pre- for the benefit of others not the conceived images of what > Minimum requirements of Post: others. “Just Culture” Card(s) “inspector” A board constructed to enable visible and visual workflow for use of post inspector will observe. >One side RED 2. When inspection is over the Clear and concise visual controls>Expose abnormalities /deficiencies Key Point: Inspection is not for >One side GREEN observer should deliberately Containers for cards (alternatives exist to eliminate need for containers) your benefit it is for the benefit >Both sides contain same to established standard condition of others with no Blame. create “internal struggle” to Instructions Standard Work Instructions for application improve the condition, Standard Schedule for Inspections>Elimination of Muda, Mura and Muri Deficiency /Abnormality corrective action tracking Discipline to Sustain contradiction should be Standard Work Instructions>Prompt and timely correction of root (Shitsuke) produced in the mind of Cards that are randomly selected for use during inspection Discipline of the users of the inspector during and after the Each card contains Standard work Training to support users of board cause of deficiency / abnormality process of Kamishibai is a must inspection. Share findings with instructions to perform an>Create an environment of Healthy and to prevent backsliding to others Learning by sharing inspection at a prescribed previous condition when there takes place. location/area at the Gemba. Example: Kamishibai Post Positive Challenge to current condition Instruction describes the “WHAT” was no check and inspection for and enable a “soon certain and positive” Key Point: Internal Struggle is to be performed in the Day Shift Night Shift standard. Name of Zone/Target Area of Inspection Focus feedback loop to immediately address focused on What SHOULD be inspection (GOOD <> NO Deficiency / Abnormality tracking Instructions abnormalities in current condition Key Point: Earn your Honor happening not what IS GOOD criteria must be specific, 1 through Discipline happening in the current clear and concise) No Muri No # No Problem />Create environment and condition of condition should occur in Confusion Good Good Abnormality Root Cause Proposed improvement (KAIZEN spirit/thinking)   Countermeasure Instructions Spirit of Humility and inspector Description The instructions are developed 2 in the inspector, individuals and Modesty from the known Standard 1 X processes in the area being inspected Kamishibai users must Conditions that must be met at Instructions have a value to be aware Closed Loop Thinking “PDCA” the location/areas where the 2 X No 8x11 paper for No standard 5 S area + set up>Create High Touch, No Tech, Low Tech that they do not know Kamishibai process MUST inspection will be conducted 3 copier in area replenish KANBAN process when needed system exists for replenishment environment for tracking corrective everything about everything. Be deliberately create a positive actions to address abnormality humble to the condition your are feedback loop so problems Standard Schedule 3 X observing and the people /abnormalities that are identified 4Foundational Skills required 4 operating in the condition when “are addressed” in a timely A “Level Loaded” schedule to>Detailed working knowledge , root performing inspection. Focus on manner for the benefit of others. perform inspections is established 5 5 understanding of the standard to be improvement. Key Point: Positive Feedback The schedule creates the condition inspected, ability to objectively know Key Point: Please be aware of loop that is CLOSED to prevent of “Shared Responsibility and Kamishibai difference of Good to a No Good Kamishibai your ignorance recurrence of abnormality. Commitment” and Balanced condition to standard being inspected Loading over time Standard Standard Work>Servant Leadership, respect, humility KAIZEN Spirit 3 Components evenly balanced Schedule Instruction>Direct observation Kamishibai users must have 悪さかげん and loaded Outgoing Incoming a value that enables Eye’s for Seeing Abnormality > WHO will conduct inspections “To be>Root Cause thinking and analysis “Completed” them to inspect an area Warusa Kagen > WHEN Calendar time (no batch) Completed”>Countermeasure production > WHERE Location/area of with improvement in mind, not “Condition of Badness”>7 Wastes just change. Kamishibai users must have the inspection>Muda Mura Muri skill of detecting small Visual Management for>PDCA Key Point: Improvement abnormalities in the current Outputs of Inspection>KAIZEN Spirit practices and activities mindset, not just to change for condition through direct sake of change . Must be a true observation Creates a public record of findings,>Eyes for Warusa Kagen benefit, not an apparent root cause, and countermeasures> Shitsuke benefit. Key Point: The ability to See (corrective actions) to be installed> Challenge Spirit abnormalities and deficiencies in location of inspection.
  • 3. Created By: Todd McCannAlternative Layouts and Workflows for Kamishibai Post Date created: 2-10-2011Alternative 1 Kamishibai (紙芝居) Subject: Kamishibai Process to support Management Observation ProgramEx: Control Room Observations > Operational Focus > Management Observation Program / Leadership Safety Audit and Leadership Safety Audit Step 1 Step 2 Step 4 Step 5 Step 3 Starting Condition >Participant removes >Participant travels >Participant places >Participant creates >Participant offers WHO: 5 participants use this post card in order 1-2-3.. to location where completed card in Condition Report for positive feedback to Each participant has committed to performing >Reviews Criteria observation will occur INCOMING Completed findings of those observed, area 1 audit per week >Prepares for >Performs container observation/audit and any owner, process owner WHEN: Weekly cycle displayed 5 days observation observation to criteria coaching that was immediately after Total audits = 5 per week on card provided, closes CR. observation. WHERE and WHAT are represented on the Monday >Observer audits area, REPEAT…Until Post >Offers coaching when card process to a known contains 1 card (#5 Friday) necessary HOW: GO SEE the area and perform audit standard completes >Execute Step 6 >Participant then card and takes Reflect on What you returns to Kamishibai STARTING Condition additional notes when learned during the audit Post At beginning of audit cycle all cards in required What will you do to post start with RED side out indicating support improvement? Description of Area or Zone to be audited (HERE) INCOMPLETE Monday Tuesday Wednesday Thursday Friday Instructions Instructions Instructions Instructions Instructions STARTING Condition Description of Area or Zone to be audited (HERE) Instructions Instructions Instructions Instructions Instructions Monday Tuesday Wednesday Thursday Friday Step 6 Instructions Instructions Instructions Instructions Instructions1 Kamishibai Post Instructions Instructions Instructions Instructions Instructions Instructions End of week Re-Loading >The LAST card (Friday #5) is the Instructions Instructions Instructions Instructions Instructions2 signal for post reload/restore. Instructions Instructions Instructions Instructions Instructions >Participant who selects last card Look for what is responsible for reload Instructions Instructions Instructions Instructions Instructions3 SHOULD be occurring Candidly dialogue >All Cards in INCOMING Instructions NOT what IS occurring with others regarding COMPLETED box are shuffled and Instructions Instructions Instructions Instructions Instructions What obstacles / barriers results of observation/audit placed at random to restore the Instructions Instructions Instructions Instructions Instructions4 Discuss current obstacles are present to meeting board to starting condition. standard condition and and barriers to meeting Description of Area or Zone to be audited (HERE) to improving current standard and potential Instructions Instructions Instructions Instructions Instructions Monday Tuesday Wednesday Thursday Friday5 condition ideas of and for Instructions Incoming Instructions (Be mindful that improvement “Completed” Abnormalities may be hidden from your view Incoming during observation) “Completed” Instructions RESTORE KAMISHIBAI POST to STARTING CONDITION
  • 4. Created By: Todd McCannAlternative Layouts and Workflows for Kamishibai Post Date created: 2-10-2011Alternative 2 Kamishibai (紙芝居) Subject: Kamishibai Process to support Management Observation ProgramEx: Control Room Observations > Operational Focus > Management Observation Program / Leadership Safety Audit and Leadership Safety Audit Step 1 Step 2 Step 5 Step 3 Step 4 Starting Condition >Participant removes >Participant travels >Participant creates >Participant offers positive >Participant places WHO: 5 participants use this post card in order 1-2-3.. to location where Condition Report for feedback to those completed card back into Each participant has committed to performing >Reviews Criteria observation will occur findings of observed, area owner, Space and Day slot from 1 audit per week >Prepares for >Performs observation/audit and any process owner immediately which it was removed WHEN: Weekly cycle displayed 5 days observation observation to criteria coaching that was after observation. >Participant places RED Total audits = 5 per week on card provided, closes CR. >Offers positive coaching side out indicating WHERE and WHAT are represented on the Monday >Observer audits area, REPEAT…Until Post when necessary deficiencies/abnormalities card process to a known contains 1 card (#5 Friday) >Participant then returns to discovered during audit HOW: GO SEE the area and perform audit standard completes >Execute Step 6 Kamishibai Post OR card and takes Reflect on What you > Participant places GREEN STARTING Condition additional notes when learned during the audit side out indicating NO At beginning of audit cycle all cards in required What will you do to deficiencies/abnormalities post start with RED side out indicating discovered during audit support improvement? INCOMPLETE Instructions STARTING Condition Monday Monday Description of Area or Zone to be audited (HERE) Instructions Instructions Monday Tuesday Wednesday Thursday Friday OR Instructions Instructions Instructions Instructions Instructions1 Instructions Step 6 Kamishibai Post Instructions End of week Re-Loading Instructions Instructions Instructions Instructions 2 >The LAST card (Friday #5) is the signal for post reload/restore. Look for what >Participant who selects last Instructions Instructions Instructions Instructions Instructions 3 SHOULD be occurring Candidly dialogue Instructions with others regarding card is responsible for reload NOT what IS occurring >All Cards on post are removed What obstacles / barriers results of observation/audit and shuffled and placed at Instructions Instructions Instructions Instructions Instructions 4 are present to meeting Discuss current obstacles random to restore the board to standard condition and and barriers to meeting starting condition. to improving current standard and potential Instructions Instructions Instructions Instructions Instructions Description of Area or Zone to be audited (HERE) 5 condition ideas of and for Instructions Monday Tuesday Wednesday Thursday Friday (Be mindful that improvement Instructions Instructions Instructions Instructions Instructions Abnormalities may be hidden from your view Instructions SPECIAL NOTE (Visual Management) Instructions Instructions Instructions Instructions during observation) Using a full view visual board alternative enables Visual trending of condition to General Public Instructions Instructions Instructions Instructions Instructions “Keep Problems Visible, do not hide in computer” More GREEN = GOOD Instructions Instructions Instructions Instructions Instructions More RED = NO GOOD Instructions Instructions Instructions Instructions Instructions RESTORE KAMISHIBAI POST to STARTING CONDITION