Kamishibai is a type of narration utilizing visual cards/boards. This originated in Japanese Buddhist

temples in the 12th century, where monks used emakimono (picture scrolls) to convey tales with

ethical driving lessons to a primarily illiterate audience.

Now it is being used as an administration device for performing audits within a manufacturing

procedure. As component of the Toyota manufacturing system (TPS), Kamishibai boards are used as

an aesthetic control for performing audits within a manufacturing procedure. A collection of cards

are placed on a board as well as picked randomly or according to schedule by supervisors as well as

supervisors of the area. This makes certain safety and security as well as cleanliness of the office is

preserved and that quality checks are being carried out.

The majority of the organizations begin with their Kaizen/Lean journey and frequently have problem

with sustenance component. The greatest obstacle for organizations is how to receive the

renovations that they have actually begun to see. There are various improvement devices like 5s,

TPM, TQM, Kaizen, Lean, 6 sigma etc that could effortlessly improve the business both short-term &

long-term. But the bigger obstacle comes when setting up processes for lasting. The majority of the

companies establish 'audits' of a brand-new process or system and think that this will guarantee

sustainability. It could definitely assist given it is done on regular basis & properly. Procedures are

set up; standard work task direction sheets/cards are produced to demonstrate how the procedure

is to be done. Supervisors then train the employee on brand-new process utilizing the job direction

sheets and after that an audit system is implemented to make sure that the workers or operators

are doing or following the process appropriately. Numerous procedures are being set up within this

style using lean tools, nonetheless, eventually the organization will certainly realize that something is

missing out on and that is when Liability can be found in image. Who is auditing? Which is inspecting

the managers, supervisors? To see to it that they are doing their part as per the procedure.

That is when organizations recognized & started utilizing Kamishibai cards as part of their audit

process. Kamishibhai was utilized in the context of the TPS for the very first time from a Canadian

previous Toyota supervisor throughout a BOUQUET seminar. In TPS Kamishibai are 21st century

matching of audits of the kaizen culture. At one factor, this systems management device was a

carefully guarded Toyota trick. Just within the last couple of years have American business began to

recognize the potential of making use of Kamishibai boards as well as cards to handle a system in a

manufacturing plant. Kamishibai cards are like cue cards or job guidelines for auditing a process. The

Kamishibai board is a visual administration tool like hr by hour manufacturing standing boards are

for managers and line managers. If hour by hr boards are made use of during the shift and on a

hourly or bi-hourly cadence, Kamishibai boards are made use of for weekly, regular monthly and

even quarterly audits. Kamishibai protects against "failure upkeep" of the Lean system itself with

audits, just as in TPM the routine devices checks prevent equipment malfunctions due to devices

putting on, overheating, and so on.

The standard strategy of the Kamishibai board as well as audit routine decreases difference between

the specific inclination, design or attention to detail in between supervisors. This reduces irregularity

in outcomes of audits in between various individuals.

Let me describe the basics of an Administration Kamishibai Card. It is an 8.5 by 11 sheet of paper

(not laminated) that is intended to be really versatile and also adjustable. Initially, fold the paper

lengthwise down the center to ensure that you have one 4.25 by 11 sheet of paper, and after that

open it back up to make sure that the fold is on top (like the roofing of a residence). This is the

"front" of the card. On the left side of the front, you ought to split it right into 4 or 5 quarters. Each

quarter represents a time of the day. Very first quarter is the first few hrs after you arrive at job. The

2nd quarter is the hours before lunch time. Third quarter is the few hrs after lunch time, as well as

the 4th quarter is the few hrs prior to you go residence. You can additionally have a quarter for

either overtime, or regular/ month-to-month tasks. In each of these, quarters should go the

"systems" that have been set up as component of your lean execution.

As pointed out earlier the Kamishibai card needs to be flexible to make sure that the supervisor,

supervisor could bring in products to your card as required as well as eliminate items from the card

when you really feel the process is controlled. Once you really feel the procedure is under control

you could additionally lower the no of audits from day-to-day to once a week to regular monthly and

so on.

Many organizations also assume that Kamishibai card is like a to-do list. Really the front left portion

of the card can be used as an order of business nonetheless that excludes among the most essential

reasons for this list and that is production of discussion between the participants of administration

and operators. During the conversation if the employee releaseds some idea manager should

document that on the rear end of the card and also do whatever they can to execute that concept.

We have actually currently discussed the front left & back left side (to tape the specifics from the

front left side). Now let's discuss the front best side. This side is very flexible. You could use it as an

area to document jobs that you should carry out follow-up tasks on an infrequent basis. If you use it

for this, then you would certainly have job # 1 on the front, "work on recognizing source for case

problems from machine 567" If you do some work on that task during the day, it must be taped on

the back best side of the card.

Few needs to carry out Kamishibai cards are to start to systematize work, to bring in liability right

into the system and also to establish much required positive dialogue between members of

administration and also the drivers that in fact do the work. As well as all this greatly helps to suffer

Kaizen/Lean implementation.

Self self-control by the administration to utilize it properly can make it take place. Part of the

administration regimen in a Lean organization is to audit existing specifications to make sure that

any kind of discrepancy could be resolved and also kaizen activity is taken. The Kamishibai is a means

to make adherence to this process visual on the gemba.

Kamishibai is extremely simple to use, and also delivers some remarkable outcomes. It can be used

to fantastic effect to develop practices & drive practices. They are low cost & fast to execute.

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