This document provides instructions for using a Kamishibai process to support management observation programs and leadership safety audits. It describes: 1) Key elements of the Kamishibai process including establishing standard inspection methods, creating a culture of respect, and embracing a spirit of continuous improvement. 2) Examples of how a Kamishibai post can be organized to track inspections, with cards assigned to different days and areas to inspect and identify deficiencies. 3) Alternative layouts and workflows for the Kamishibai post, including options for placing completed cards and reloading the post at the end of each week.

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 GEMBA
We Teach Leaders to “Learn to See” and “Serve the Gemba”

2. Created By: Todd McCann
Focus 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 support
Establish standard inspection discipline and Management Observation Program
method focused on a specific area/zone Mindsets & Behaviors and Leadership Safety Audit
Materials required
using direct observation combined with Foundation Skills and Conditions
detailed knowledge of formal standards in
area, with an aim to ensure standard is
being achieved, sustained and improved. KAMISHIBAI POST
CULTURE of RESPECT Challenge Spirit
Key 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 inspeciton
>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 inspector conceived images of what
> Minimum requirements of Post:
others. “Just Culture” Card(s)
A board constructed to enable visible and visual workflow for use of post
>Expose abnormalities /deficiencies inspector will observe. >One side RED
2. When inspection is over the
Clear and concise visual controls
to established standard condition 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
create “internal struggle” to Standard Work Instructions for application
>Elimination of Muda Mura and Muri of others with no Blame. Instructions
improve the condition, Standard Schedule for Inspections
>Prompt and timely correction of root Discipline to Sustain contradiction should be Standard Work Instructions Deficiency /Abnormality corrective action tracking
cause of deficiency / abnormality (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
>Create an environment of Healthy and process of Kamishibai is a must inspection. Share findings with instructions to perform an
Positive Challenge to current condition 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
and enable a “soon certain and positive” Instruction describes the “WHAT”
was no check and inspection for
feedback loop to immediately address Key Point: Internal Struggle is to be performed in the Day Shift Night Shift
standard. Name of Zone/Target Area of Inspection Focus
abnormalities in current condition focused on What SHOULD be inspection (GOOD <> NO
Deficiency / Abnormality tracking
Instructions
Key Point: Earn your Honor happening not what IS GOOD criteria must be specific,
>Create environment and condition of happening in the current clear and concise) No Muri No
1
through Discipline # No Problem /
improvement (KAIZEN spirit/thinking) condition should occur in Confusion Good
Good Abnormality Root Cause
Proposed
in the inspector, individuals and p  
Countermeasure
Instructions
Spirit of Humility and inspector Description
The instructions are developed 2
processes in the area being inspected Modesty from the known Standard 1 X
Kamishibai users must Conditions that must be met at
>Create High Touch, No Tech, Low Tech
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
environment for tracking corrective 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
actions to address abnormality everything about everything. Be deliberately create a positive
Foundational Skills required humble to the condition your are feedback loop so problems Standard Schedule 3 X
observing and the people /abnormalities that are identified 4
>Detailed working knowledge , root operating in the condition when “are addressed” in a timely A “Level Loaded” schedule to 4
understanding of the standard to be performing inspection. Focus on manner for the benefit of others. perform inspections is established
5 5
inspected, ability to objectively know improvement.
Key Point: Positive Feedback The schedule creates the condition
difference of Good to a No Good
Key Point: Please be aware of loop that is CLOSED to prevent of “Shared Responsibility and Kamishibai
condition to standard being inspected Kamishibai
your ignorance recurrence of abnormality. Commitment” and Balanced
>Servant Leadership, respect, humility Loading over time Standard Standard Work
>Direct observation KAIZEN Spirit 3 Components evenly balanced Schedule Instruction
>Root Cause thinking and analysis 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
>Countermeasure production “Completed”
them to inspect an area Warusa Kagen > WHEN Calendar time (no batch) Completed”
>7 Wastes > WHERE Location/area of
with improvement in mind, not “Condition of Badness”
>Muda Mura Muri just change. Kamishibai users must have the inspection
>PDCA skill of detecting small Visual Management for
>KAIZEN Spirit practices and activities Key Point: Improvement abnormalities in the current Outputs of Inspection
>Eyes for Warusa Kagen mindset, not just to change for condition through direct
sake of change . Must be a true observation Creates a public record of findings,
> Shitsuke
benefit, not an apparent root cause, and countermeasures
> Challenge Spirit benefit. Key Point: The ability to See (corrective actions) to be installed
abnormalities and deficiencies in location of inspection.

3. Created By: Todd McCann
Alternative Layouts and Workflows for Kamishibai Post Date created: 2-10-2011
Alternative 1 Kamishibai (紙芝居) Subject: Kamishibai Process to support
Management Observation Program
Ex: 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
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Monday Tuesday Wednesday Thursday Friday
Step 6
Instructions
Instructions
Instructions
Instructions
Instructions
1
Kamishibai Post
Instructions
Instructions
Instructions
Instructions
Instructions
Instructions
End of week Re-Loading
>The LAST card (Friday #5) is the
Instructions
Instructions
Instructions
Instructions
Instructions
2
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
Instructions
3 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
Instructions
4 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 Friday
5
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 McCann
Alternative Layouts and Workflows for Kamishibai Post Date created: 2-10-2011
Alternative 2 Kamishibai (紙芝居) Subject: Kamishibai Process to support
Management Observation Program
Ex: 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
Instructions
1
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
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Instructions
during observation)
Using a full view visual board alternative enables
Visual trending of condition to General Public
Instructions
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“Keep Problems Visible, do not hide in computer”
More GREEN = GOOD
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More RED = NO GOOD
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Instructions
RESTORE KAMISHIBAI POST to STARTING CONDITION