e-Kaizen Solutions - www.tpm-us.
com
Cultivating for Proactive Philosophy
World-Class Manufacturing Excellence e-Kaizen Solutions by PM Systems Corporation
Shinichi Shinotsuka
Kaizen Consultant www.tpm-us.com
[email protected] e-Kaizen Solutions - www.tpm-us.com
Shinichi Shinotsuka, e-Kaizen Consultant
www.tpm-us.com / [email protected] 1023 Muirfield Drive Marietta, Georgia 30068 USA Phone 770-575-1934 Fax 770-578-9784
e-Kaizen Solutions - www.tpm-us.com
Never do things by halves
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2003-2007 by PM Systems Corporation
e-Kaizen Solutions - www.tpm-us.com
Total Process Management
Strategy (Where we are going)
Performance Evaluation (Indicators)
Information Develop Make Sell Customer
Rotate this Cycle (Develop-Make-Sell) quickly
Level-1 Level-2 Level-3
Leadership
Managerial Organization
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2003-2007 by PM Systems Corporation
e-Kaizen Solutions - www.tpm-us.com
Preparation Stage - Step-0 Pre-consulting Visit & Needs Analysis
External Needs Market & Products - Market share & Positioning Customers Wants Internal Needs Man (Skill) - Technical skill & Managerial skill Machine - Machine losses & Machine state Material - Suppliers & SKU Methods - Manufacturing process
How will managerial organization change? 9Managers role 9Supervisors role & Operators role
What indicators should we focus? 9Data Collection & Reporting systems 9Goal-sharing system 9Progress monitoring & follow up
What milestones should we setup? 9Pillars 9Connect with Corporate Strategy & Goal
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2003-2007 by PM Systems Corporation
e-Kaizen Solutions - www.tpm-us.com
e-Kaizen Solutions Zero losses in Manufacturing System
e-Kaizen Process Scorecard Leadership
Steering Committee Goal Sharing Step Diagnosis + Top Diagnosis Progress Control Kaizen/TPM Facilitators Overlapping Small Group Daily Management
8 Pillars Deployment
Autonomous Maintenance Planned Maintenance Focused Improvement Training & Education Early Management Quality Assurance & Maintenance Administrative operations Kaizen Safety & Environment Total Productive Maintenance
Performance Review
Kaizen/TPM KPI P-Q-C-D-S-M Daily Data + Monthly Summary Benchmark (Baseline) Data Cascade Trend Control Zero-Oriented Target
Total Perfect Manufacturing
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2003-2007 by PM Systems Corporation
e-Kaizen Solutions - www.tpm-us.com
e-Kaizen Workshop Process Flow Chart
Basic Workshop Flow e-Kaizen - Workshop (S) Start-up Course (Basic) (F-1) Basic Facilitator (P) Planned Maintenance for Zero Breakdowns (Q) Quality Pillar (Basic) (C) Right First Time Changeover (I) Intermediate Facilitator (A) Advanced Facilitator e-Kaizen - Workshop requires Actual Case Studies at a workshop host plant. -Typical Preparations are; - Practical Machines - Machine Operation Manuals & Standards - Maintenance (Downtime) Log - Production Record (Shift / Daily) - Quality Defects Log
Workshop Design Meeting (On-Site / Off-Site)
< 1 week Workshop Fee Estimation
1 Day On-Site Workshop Preparation
4 6 Weeks Workshop Host Plant
e-Kaizen Workshop
1-2 Weeks Summary & Review Report
e-Kaizen - Workshop Course Agenda
e-Kaizen Workshop Review
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2003-2007 by PM Systems Corporation
e-Kaizen Solutions - www.tpm-us.com
(S) Start-up Course (Basic)
1st Day 2nd Day 1st Day Review 5S & Safety Team Presentation AM Step-1 3rd Day 2nd Day Review AM Step-1 Team Presentation Focused Improvement (Break) 5S & Safety Team Practice (1) Hands-On Practice (1) 5S & Safety 5S Board Preparation Close Planned Maintenance FI CAP-Do Cycle Final Presentation 4th Day 3rd Day Review FI CAP-Do Presentation Training&Education
Who attend; Manager, Supervisor What; Learn Kaizen Basic Team-Building TPM Overview Data Analysis When; 4 Days Where; Host Plant How; On-Site Practice Fee - $2200 per day + Training Materials
8:30 8:40 9:00 10:00 11:00 11:20 12:30 13:25 14:00 17:30 18:00 21:30
8:40 9:00 10:00 11:00 11:20 12:30 13:25 13:55 17:30 18:00 21:30
Registration Course Overview Team Building Practice Kaizen/TPM Overview
Lunch Team Practice (2) Team Practice (3) Hands-On Practice (2) Hands-On Practice (3) AM Step-1 FI CAP-Do (Break) AM-1 Board Presentation FI CAP-Do Board Close Close
Preparation Materials 1) Cap - 4 colors (each-8) (Red/Yellow/Blue/Orange) 2) Polo Shirts 3) F-Tags 3-1 Red - 500 3-2 Blue - 500 3-3 Yellow (Safety) - 500 4) OPLs - 500 5) Card Board for Presentation 4 x 4 x 2 (1m X 1m)=32 boards 6) Team Practice Supplies 6-1 Board Maker (Black/Red/Green etc.) 6-2 Scotch Tape & Duct Tape 6-3 Color Paper (Craft Paper) 6-4 Staple 6-5 Ruler 6-6 Scissors * Host Plant prepares Yellow Highlighted items
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2003-2007 by PM Systems Corporation
e-Kaizen Solutions - www.tpm-us.com
(F-1) Basic Facilitator
Kickoff for World Class Manufacturing Excellence Trainers Training Roadmap
Caution
In preparation stage, Train every Manager, Supervisor, Team Leaders To Create Kaizen Trainer.
PM for Zero Breakdowns 3 Days
Start-up Course 4 Days Basic
e-Kaizen Pre-Consulting Meeting
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2003-2007 by PM Systems Corporation
e-Kaizen Solutions - www.tpm-us.com
PM (Planned Maintenance) Workshop
Who attend; Maintenance Supervisor Kaizen Trainers* - who attended (S) Start Up Course What; Learn Kaizen Basic PM 8-Element Approach Logical Root-Cause Analysis 5S & Visual Control Data Analysis When; 2 Days Where; Host Plant How; On-Site Practice Fee; $2200 per day + Training Materials
Preparation Materials Case Study 1) Cap - 4 colors (each-8) 1) Actual Broken Parts (Red/Yellow/Blue/Orange) 2) Maintenance Log 2) Polo Shirts 3) Machine Operation Manual 3) F-Tags 3-1 Red - 500 3-2 Blue - 500 3-3 Yellow (Safety) - 500 4) OPLs - 500 5) Card Board for Presentation 4 x 4 x 2 (1m X 1m)=32 boards 6) Team Practice Supplies 6-1 Board Maker (Black/Red/Green etc.) 6-2 Scotch Tape & Duct Tape 6-3 Color Paper (Craft Paper) 6-4 Staple 6-5 Ruler 6-6 Scissors * Host Plant prepares Yellow Highlighted items 1st Day 8:30 8:40 9:00 10:00 11:00 11:20 12:30 13:25 14:00 17:30 18:00 21:30 8:40 9:00 10:00 11:00 11:20 12:30 13:25 13:55 17:30 18:00 21:30 Logical Root-Cause Analysis Breakdown Analysis Registration Course Overview Team Building Practice Planned Maintenance Overview 2nd Day 1st Day Review Team Presentation 5S (Spare Part & PM Workshop) (Break) 5S Spare Part Room & Workshop Lunch Team Practice (1) Hands-On Practice (1) Breakdown Analysis (Break) Presentation Board Close Team Practice (2) Final Presentation (14:30 - 16:00) PM
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2003-2007 by PM Systems Corporation
e-Kaizen Solutions - www.tpm-us.com
Quality Pillar Workshop QM 10 Step Deployment
1st Day 2nd Day 1st Day Review Step-5 & 6 CAP-Do Cycle QM 10 Step Deployment Step-7 To Step-10 (Break) QM 10 Step Deployment Step-1 To Step-6 Lunch Team Practice (1) Hands-On Practice (1) Step-1 To Step-4 (Break) Logical Root-Cause Analysis Close Team Practice (2) Final Presentation (14:30 - 16:00) QM 10 Step Deployment Step-7 To Step-10
Who attend; Quality Supervisor & Leaders Process Engineers Kaizen Trainers* - who attended (S) Start Up Course What; Learn Kaizen Basic Quality Assurance & Maintenance QA & QM Matrix QM 10 Step Deployment Data Analysis When; 2 Days Where; Host Plant How; On-Site Practice Fee; $2200 per day + Training Materials
8:30 8:40 9:00 10:00 11:00 11:20 12:30 13:25 14:00 17:30 18:00 21:30
8:40 9:00 10:00 11:00 11:20 12:30 13:25 13:55 17:30 18:00 21:30
Registration Course Overview Team Building Practice Quality Pillar Overview
Preparation Materials Case Study 1) Cap - 4 colors (each-8) 1) "Evidence" - Actual Samples (Red/Yellow/Blue/Orange) 2) Quality Defects Data (Log) 2) Polo Shirts 3) Maintenance Log 3) F-Tags 4) Machine Operation Manuals 3-1 Red - 500 3-2 Blue - 500 3-3 Yellow (Safety) - 500 4) OPLs - 500 5) Card Board for Presentation 4 x 4 x 2 (1m X 1m)=32 boards 6) Team Practice Supplies 6-1 Board Maker (Black/Red/Green etc.) 6-2 Scotch Tape & Duct Tape 6-3 Color Paper (Craft Paper) 6-4 Staple 6-5 Ruler 6-6 Scissors * Host Plant prepares Yellow Highlighted items
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2003-2007 by PM Systems Corporation
e-Kaizen Solutions - www.tpm-us.com
e-Kaizen - Coaching & Workshop Milestone
Awareness Confusion Understanding Interest Fun
Preparation 6-12 months
Pre-Consulting Visit
Expansion 12 months Kickoff
Implementation 12 months
Consolidation > 12 months
Leadership Start-up Course
Machine changes
QM 10 Step Deployment RFT-Changeover
Right First Time
Mindset changes
Autonomous Maintenance Step-4 General Inspection Preparations
PM for Zero Breakdowns
zBe fun with Kaizen! e-Kaizen Kaizen Consultant
Early Equipment Management M-P Database & Design Review
General Inspection 100 % Operators Initial Clean
Managers & Team leaders
AM Standard SOCS & HTA
zThrough sharing many good examples, Operators are familiar with a Team Working and zDevelop Zero Case Studies
zThrough many case studies to eliminate SOCS, Operators take interest in Kaizens and 100 % employee can use Basic Kaizen Tools (Methodology)
Instructors & Facilitators Training
zThrough cleaning up every piece of component in equipment, People understand how machine works correctly
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2003-2007 by PM Systems Corporation
e-Kaizen Solutions - www.tpm-us.com
The Basic Concept of e-Kaizen
Number of Equipment Breakdowns Trend - Example
Number
10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 0
ar k M m
Improve
Maintain
Prevent Recurrence
Prevent Problems
Be nc h
on th 12 m on th 18 m on th 24 m on th 30 m on th 31 m on th 32 m on th 33 m on th
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2003-2007 by PM Systems Corporation
