4. 4
The story of a traveler
Once upon a time, one traveler was walking on the street.
And he found a man is piling stones. He asked the man.
" What are you doing ?"
The man replied. " You can see, I am piling the stones."
Next day, the traveler came to the same place and found
the different man is doing the same, so he asked again.
" What are you doing ?"
The man replied. "I am building a church."
And next day, the traveler came to the same place again
and found the other different man is doing the same thing,
so he asked the same question.
" What are you doing ?"
The man replied. " I am making the place for curing people's heart which
we call a church."
Mikami, Tamotsu
6. 6
The Job ( Work )
1. Life for money ( To contribute )
What is the Job?
2. Money for life ( To live )
The Job has a meaning Value creation
Purpose Time limit
Mikami, Tamotsu
7. 7
Why do we implement actions such as TQM or Lean ?
Real meaning of actions
Satisfaction
Good quality ? Customer Prosperity
Good efficiency ? Earn money Better life stakeholder
Good productivity ? Social contribution Employee
Method Mikami, Tamotsu Purpose
8. 8
Purpose = Satisfaction for everybody
In order to increase
Our goal 10% increase share profit
5S
Lean
Lean In order to
SWOT
Method improve
Tool Training situation
TQM 6σ
Audit
Q RTY, Q. cost ( PAF )
Daily In order to
control C PCR, Many Data
take action
item
D Lead time, Stock,
Nature ( Strength ) of the company : High Technology and Spirit
Mikami, Tamotsu
9. 9
My desire
The people work here in the company can
say we work for one of the satisfaction
( purpose ), not a method.
Method Purpose
1st man piling stones
2nd man piling stones building a church
3rd man building a church making a cure place
Mikami, Tamotsu
10. 10
We are working for customers
Who is my customer ?
My customer is not an end user of our products, but I have an internal
company customer.
A job must be created a value to the next process
feedback feedback
Someone = Someone =
my supplier Myself my customer
Add value Add value Add value
Mikami, Tamotsu
11. 11
Thinking Time
Who is your customer ?
Who is your supplier ?
Mikami, Tamotsu
12. 12
The story of " Beware of fire"
In a very dry season, a chemical company president called all the factory
managers and said " Beware of fire " to them.
Within a day, the factory managers called all department managers and
said " Beware of fire ".
Then immediately the department managers called the team leaders and
said " Beware of fire ".
The team leaders did the urgent meeting for all employees and inform "
Beware of fire ".
The top announcement was distributed within all employees in one day.
But unfortunately this company had a fire and lost many properties.
WHY ? Mikami, Tamotsu
13. 13
The fire department reported that the cause of the fire
was the cigarette. The cigarette lights led the fire to
the cardboard boxes near the rest area.
Probably one employee thought he distinguished the
cigarette and threw it away into the ash tray.
Everybody returned home after the break.
There were many cardboards stuck behind the rest area.
The distinguisher was located near the rest area. A fire
bucket was placed near the ash tray.
There were many magazines and newspaper were on
the table in the rest area.
Mikami, Tamotsu
14. 14
What was the problem ?
and
What should have done ?
Mikami, Tamotsu
15. 15
There are two major problem.
1. Bad break down
2.Not check the reality
Mikami, Tamotsu
16. 16
Break down
• In a company, in order to accomplish the business target
smoothly, we stricture the organization.
• Each layer of the people have a role and responsibility.
• What is the factory manager's RR and so on ?
• They should not say the same words as the president said.
• They should instruct to the department managers to make
the list of all the potential cause of fire and report the
current situation by when.
• Then the department managers should prepare the list with
the team leaders and check by themselves.
• The team leader should make the periodical check list and
display the potential locations for operators to check.
• Break down must be the instruction to next and receive the
result. Mikami, Tamotsu
17. 17
Check the reality
• As far as the people working at the manufacturing
business, we have to recognize the production spot is like
a creature.
• Always the situation is changing.
• The managers roles are basically 5 items.
1. (Q) Quality --- Products meet the specification
2. (C) Cost --- Highest efficiency and less waste
3. (D) Delivery --- Daily completion
4. (M) Management ---- Education to employees
5. (S) Safety --- Keep properties ( Man & Machine )
• Check by yourself by your own eyes to find concerns
• It goes without saying that the each layer of the person
will be decided by the ability of how much wide and deep
concern can be raised accurately.
Mikami, Tamotsu
18. 18
Ladder of Abstraction
Word Action
Beware of fire Keep property for
President
customer and employees Abstract
Safety assurance Company wide potential
Director risk analysis
Risk assessment Daily walk in the plant
Plant Manager
Department Visualization / Check and take
Manager Self check immediate action
Education & Define individual areas
Team Leader
training of responsibility
Daily check Positive participation
Operator
Concrete
" Ladder of Abstraction " is from Language in Thought and Action by Mr. S.I Hayakawa & Alan R. Hayakawa
Mikami, Tamotsu
19. 19
About 5S
• What is the purpose ?
• If we everybody can follow this activities, who is
becoming happy ?
• Is this a clean up Champaign ?
Mikami, Tamotsu
20. 20
5S is for your customer satisfaction
5 S makes our work environment organized.
nice and clean feeling working environment
Method
less waste time and quick response
speed up business This must be KPI of 5S
Purpose
customer's happiness Mikami, Tamotsu
21. 21
10 items for 5S
1. To be easy to see and understand ( Use color, Less word more
picture and accept new comer opinion )
2. To be clearly noticed the abnormal situation ( Red lamp, Hazard
buzzer, Visualization )
3. To be linked to the training program ( Small group activity ---
Everybody has to be a leader in the period of time )
4. To be decided the individual area and allocate the responsibility
( Display the map with a name of colored area clearly )
5. To create excellent environment of shop floor ( 5S patrol, 5S
meeting )
6. To share “ Mottainai ( What a waste )” sense ( Save energy, water,
electricity, paper and meeting time )
7. To listen to the operators voice ( Ask the new associates “ What is
difficult to understand?” and “ What is difficult to do?”
8. To take 10 minutes everyday ( Define the detail plan to do for
everyone )
9. To hold the presentation ( Motivate group and prize them )
10. To introduce other good idea ( Do not hesitate to copy the idea )
Mikami, Tamotsu
22. 22
Effectiveness of 5 S
1. Improve quality
2. Cost down
3. Delivery stability
4. Improve productivity
5. Lead time reduction
6. Inventory reduction
7. Safety environment
8. Motivation up
9. Team work
10. Improve profit
Mikami, Tamotsu
23. 23
Why improvement initiatives fail to sustain?
Many companies are frustrated with Kaizen
improvement Initiatives and say that it won’t
work…..
Mikami, Tamotsu
24. 24
Check the reality
Management is not clear of purpose
Invisible Management is not convinced of change
concern Unable to control contradictions
Phenomena
Management does not recognize
importance to align change in behavior
Only talk no action
No change in organization
No empowerment of people
Symptom KPI keep change
People are not clear the objectives
Find it more of a burden
The tools are launched
People are trained
Visible Event
Management priority changes often
concern Another initiative is launched
Mikami, Tamotsu
25. 25
Summary
Every activities have a meaning
• Once the activities are introduced or broken
down to the actual people to act, they must fully
understand the real purpose and the expecting
outcome through the activity.
• Secondary they must study how to approach and
how much energy they must spend to realize the
result satisfactory.
• Then the each layer of people have to clearly
recognize and define what, why, when, where,
who, how to and how many in the plan.
Mikami, Tamotsu
