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e-Kaizen Solutions - www.tpm-us.com

World-Class Manufacturing Excellence

e-Kaizen Solutions byPM Systems Corporation

Shinichi Shinotsuka

Kaizen Consultant

www.tpm-us.com

[email protected]

Cultivating for Proactive Philosophy

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Shinichi Shinotsuka, eShinichi Shinotsuka, e--KaizenKaizen ConsultantConsultant

www.tpm-us.com / [email protected]

1023 Muirfield Drive Marietta, Georgia 30068 USA

Phone 770-575-1934 Fax 770-578-9784

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2003-2007 by PM Systems CorporationPage-2


Never do things by halves

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Total Process Management

Information

CustomerDevelop Make Sell

Leadership

Rotate this Cycle (Develop-Make-Sell) quickly

Managerial Organization

Strategy (Where we are going)

Performan

ceEvaluation

(Ind

icators)

Level-1

Level-2

Level-3

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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

What indicators should we focus?

9Data Collection & Reporting systems

9Goal-sharing system9Progress monitoring & follow up

How will managerial organization change?

9Managers role

9Supervisors role & Operators role

What milestones should we setup?

9Pillars

9Connect with Corporate Strategy & Goal

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e-Kaizen Solutions

Autonomous Maintenance

Planned Maintenance

Focused Improvement

Training & Education

Early Management

Quality Assurance & Maintenance

Administrative operations KaizenSafety & Environment

Steering Committee

Goal Sharing

Step Diagnosis + Top Diagnosis

Progress Control

Kaizen/TPM Facilitators

Overlapping Small Group

Daily Management

Kaizen/TPM KPI

P-Q-C-D-S-M

Daily Data + Monthly Summary

Benchmark (Baseline)

Data Cascade

Trend Control

Zero-Oriented Target

Leadership 8 Pillars Deployment Performance Review

e-Kaizen Process Scorecard

Zero losses in Manufacturing System

Total Perfect Manufacturing

Total Productive Maintenance

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e-Kaizen Workshop Process Flow Chart

1 Day On-Site

Workshop Preparation

Workshop Design Meeting

(On-Site / Off-Site)

e-Kaizen Workshop

e-Kaizen Workshop

Review

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 Facilitatore-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

< 1 week

Workshop Fee Estimation

4 6 Weeks

Workshop Host Plant

1-2 Weeks

Summary & Review Report

e-Kaizen - Workshop

Course Agenda

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(S) Start-up Course (Basic)

1st Day 2nd Day 3rd Day 4th Day

8:30 8:40 Registration 1st Day Review 2nd Day Review 3rd Day Review

8:40 9:00 Course Overview

9:00 10:00 Team Building Practice

10:00 11:00 Kaizen/TPM Overview AM Step-1 Focused Improvement Training&Education

11:00 11:20

11:20 12:30 5S & Safety Planned Maintenance FI CAP-Do Cycle Final Presentation

12:30 13:25

13:25 13:55 Team Practice (1) Team Practice (2) Team Practice (3)

Hands-On Practice (1) Hands-On Practice (2) Hands-On Practice (3)

5S & Safety AM Step-1 FI CAP-Do

17:30 18:00

18:00 21:30 5S Board Preparation AM-1 Board Presentation FI CAP-Do Board

Close Close Close

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 Presentation4 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

(Break)

Lunch

(Break)

Preparation Materials

14:00 17:30

21:30

5S & Safety Team

Presentation

AM Step-1 Team

PresentationFI CAP-Do Presentation

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

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(F-1) Basic Facilitator

Trainers TrainingTrainers Training

RoadmapRoadmap

e-Kaizen

Pre-Consulting Meeting

PM for Zero BreakdownsPM for Zero Breakdowns

3 Days3 Days

StartStart--up Courseup Course4 Days Basic4 Days Basic

Kickoff forKickoff for World ClassWorld ClassManufacturing ExcellenceManufacturing Excellence

CautionIn preparation stage,

Train every Manager,

Supervisor,

Team Leaders

To

CreateKaizen Trainer.

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PM (Planned Maintenance) Workshop

1st Day 2nd Day

8:30 8:40 Registration 1st Day Review



10:00 11:00 Planned Maintenance Overview 5S (Spare Part & PM Workshop)

11:00 11:20

11:20 12:30Logical Root-Cause Analysis -

Breakdown Analysis

5S

Spare Part Room & PMWorkshop

12:30 13:25

13:25 13:55 Team Practice (1) Team Practice (2)

Hands-On Practice (1)

Breakdown Analysis

17:30 18:00 (Break)

18:00 21:30 Presentation Board

Close

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


4) OPLs - 500

5) Card Board for Presentation

4 x 4 x 2 (1m X 1m)=32 boards





6-4 Staple

6-5 Ruler

6-6 Scissors

Team Presentation


(Break)

Lunch


14:00 17:30

21:30

Final Presentation

(14:30 - 16:00)

Who attend;

Maintenance Supervisor

Kaizen Trainers*

- who attended (S) Start Up Course


PM 8-Element Approach

Logical Root-Cause Analysis

5S & Visual Control

Data AnalysisWhen; 2 Days

Where; Host Plant


Fee; $2200 per day + Training Materials

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Quality Pillar Workshop QM 10 Step Deployment1st Day 2nd Day

8:30 8:40 Registration 1st Day Review



10:00 11:00 Quality Pillar OverviewQM 10 Step Deployment

Step-7 To Step-10

11:00 11:20

11:20 12:30QM 10 Step Deployment

Step-1 To Step-6

QM 10 Step Deployment

Step-7 To Step-10

12:30 13:25

13:25 13:55 Team Practice (1) Team Practice (2)

Hands-On Practice (1)

Step-1 To Step-4

17:30 18:00 (Break)

18:00 21:30 Logical Root-Cause Analysis

Close

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


4) OPLs - 500

5) Card Board for Presentation

4 x 4 x 2 (1m X 1m)=32 boards





6-4 Staple

6-5 Ruler

6-6 Scissors

Step-5 & 6

CAP-Do Cycle


(Break)

Lunch


14:00 17:30

21:30

Final Presentation

(14:30 - 16:00)

Who attend;

Quality Supervisor & Leaders

Process Engineers

Kaizen Trainers*

- who attended (S) Start Up Course


Quality Assurance & Maintenance

QA & QM Matrix


Data Analysis

When; 2 Days

Where; Host Plant


Fee; $2200 per day + Training Materials

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e-Kaizen - Coaching & Workshop Milestone

Preparation Expansion Implementation Consolidation

6-12 months 12 months 12 months > 12 months

ee--KaizenKaizen

ConsultantConsultant

Instructors &

Facilitators Training

UnderstandingAwareness Confusion Interest Fun

SOCS & HTA

AM Standard

General Inspection

zThrough cleaning up every piece of component in equipment, People

understand how machine works correctly

zThrough many case studies to eliminate SOCS, Operators take interest in Kaizens

and 100 % employee can use Basic Kaizen Tools (Methodology)

Machine changes

KickoffKickoff

zBe fun with Kaizen!

zThrough sharing many good examples,

Operators are familiar with a Team Working andzDevelop Zero Case Studies

Mindset changes

Managers & Team leaders

Initial Clean

Start-up Course

PM for Zero Breakdowns


RFT-ChangeoverRight First Time

Autonomous Maintenance

Step-4 General Inspection Preparations

Early Equipment Management

M-P Database & Design Review

Leadership

100 % Operators

Pre-Consulting Visit

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Number of Equipment Breakdowns Trend - Example

0

1000

2000

3000

4000

5000

6000

7000

80009000

10000

BenchM

ark

6month

12month

18month

24month

30month

31month

32month

33month

Number

Improve Maintain

Prevent Recurrence Prevent Problems

The Basic Concept ofe-Kaizen

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