Genchi Genbutsu

Genchi Gembutsu is a fundamental principle in the Lean Management system that emphasizes the importance of going to the source to observe and understand problems and opportunities. This concept was developed by Taiichi Ohno, one of the pioneers of the Toyota Production System (TPS), which is widely recognized as the precursor to Lean Management. Genchi Gembutsu is a Japanese term that translates to "go and see for yourself."

In the manufacturing industry, Genchi Gembutsu is best utilized to identify problems and opportunities in the production process. It involves visiting the production line to observe how work is being done, asking questions, and getting feedback from the workers. By going to the source, managers and leaders can see firsthand the challenges and issues that workers face on the job, and gain a deeper understanding of how the production process works.

The use of Genchi Gembutsu in the manufacturing industry is important because it allows managers to gain a comprehensive understanding of the production process, from start to finish. This includes understanding the inputs and outputs of each stage of the process, as well as the equipment and tools used. By doing so, managers can identify inefficiencies and areas where waste is being produced, and take action to eliminate these issues.

Genchi Gembutsu can also be used to identify opportunities for improvement in the production process. By observing how work is being done, managers can identify areas where work can be streamlined, and where productivity can be increased. This may involve rearranging the production line, investing in new equipment, or improving worker training and education.

One of the key benefits of Genchi Gembutsu is that it fosters a culture of continuous improvement within the organization. By encouraging managers to go to the source and observe how work is being done, organizations can identify and eliminate problems in real-time. This helps to create a more efficient and effective production process, which can lead to increased productivity and profitability.

In a nutshell, Genchi Gembutsu is a critical concept in the Lean Management system, particularly in the manufacturing industry. By going to the source to observe and understand the production process, managers can identify and eliminate inefficiencies and waste, and identify opportunities for improvement. By fostering a culture of continuous improvement, organizations can create a more efficient and effective production process, which can ultimately lead to increased productivity and profitability.

Break Through Objectives

Operational Excellence experts know the importance of establishing clear, measurable, and achievable goals in any organization. This is particularly true in the realm of Lean Management, where continuous improvement is key to success. In this context, Breakthrough Objectives play a vital role in driving progress and achieving sustainable change.

But what are Breakthrough Objectives and why are they so important? Simply put, Breakthrough Objectives are ambitious, long-term goals that aim to transform an organization and its processes. They go beyond the traditional incremental improvements that Lean Management focuses on, and aim for truly radical change. By establishing Breakthrough Objectives, organizations can focus their efforts on the most important improvements and create a clear vision for their future.

So, how can a Lean organization successfully implement and adopt Breakthrough Objectives? There are several key steps to follow:

1. Clarify the vision: Before setting Breakthrough Objectives, it is important to have a clear understanding of the organization’s vision and direction. This vision should align with the values and principles of Lean Management, and should be communicated clearly to all stakeholders.

2. Define the objectives: Once the vision is clear, it is time to define the Breakthrough Objectives. These should be specific, measurable, and achievable, and should align with the organization’s vision. It is also important to prioritize the objectives based on their importance and impact.

3. Engage all stakeholders: Implementing Breakthrough Objectives is a team effort, and it is crucial to engage all stakeholders in the process. This includes employees, customers, suppliers, and other key partners. By involving these stakeholders, organizations can ensure that their Breakthrough Objectives align with their needs and expectations.

4. Establish a clear strategy: To achieve the Breakthrough Objectives, a clear strategy must be established. This strategy should include the steps required to achieve the objectives, the resources needed, and the timeline for implementation. The strategy should also include measures for monitoring and evaluating progress.

5. Provide training and support: To ensure that the Breakthrough Objectives are successfully implemented, employees must be trained and supported. This may include training on Lean Management principles and practices, as well as training on new systems and processes. Employees must also be provided with the resources they need to succeed, including the right tools and equipment.

6. Monitor and evaluate progress: It is important to regularly monitor and evaluate progress against the Breakthrough Objectives. This helps organizations to identify areas for improvement and make adjustments as needed. By continuously monitoring and evaluating progress, organizations can ensure that they stay on track and make the necessary changes to achieve their goals.

7. Celebrate success: Finally, it is important to celebrate success when the Breakthrough Objectives are achieved. This helps to reinforce the importance of Lean Management principles and practices, and encourages employees to continue working towards further improvements.

In a nutshell, Breakthrough Objectives are an important tool for driving change in a Lean organization. By following these steps, organizations can successfully implement and adopt Breakthrough Objectives, and achieve truly transformative results. With a clear vision, a solid strategy, and a commitment to continuous improvement, organizations can achieve their goals and achieve Operational Excellence.

Rapid Improvement Event

Rapid Improvement Events, also known as Kaizen events, are a powerful tool for improving production processes in the manufacturing industry. They are focused, short-term initiatives aimed at solving specific problems and improving processes in a rapid and efficient manner.

At the heart of a Rapid Improvement Event is the involvement of a cross-functional team of employees, each bringing a unique perspective and skillset to the table. The team works together to identify and solve problems, test new ideas, and implement solutions that can have an immediate impact on the production process.

One of the key benefits of Rapid Improvement Events is the speed with which they can deliver results. By focusing on a specific problem and working together as a team, significant improvements can be made in just a few days or weeks. This can be especially valuable in the manufacturing industry, where time is often of the essence and even small improvements can make a big difference.

To ensure the success of a Rapid Improvement Event, it's important to follow a structured methodology. This typically includes the following steps:

1. Define the problem and scope of the event. What is the specific issue that needs to be addressed, and what is the desired outcome of the event?

2. Assemble the cross-functional team. Choose team members who have a strong understanding of the problem and can bring a variety of skills and perspectives to the table.

3. Conduct a thorough analysis of the problem. Gather data, observe processes, and engage in root cause analysis to understand the underlying cause of the problem.

4. Develop and implement a plan of action. Based on the findings of the analysis, create a plan of action that addresses the root cause of the problem and implements solutions that will improve the production process.

5. Implement and monitor the changes. Once the plan of action is in place, implement the changes and monitor the results to ensure they are having the desired impact.

6. Reflect and celebrate successes. Reflect on the successes of the event and celebrate the improvements that were made.

Rapid Improvement Events are a powerful tool for improving production processes in the manufacturing industry. By bringing together a cross-functional team, focusing on a specific problem, and following a structured methodology, organizations can achieve significant improvements in a short amount of time.

In a nutshell, it is important to embrace a continuous improvement mindset and actively seek out opportunities to improve production processes. Rapid Improvement Events provide a structured and efficient way to do just that, delivering results that can have a lasting impact on an organization's success.

Annual Objectives

The use of annual objectives with 3 to 5 years breakthrough objectives is a crucial aspect of policy development in an organization. This approach to setting goals allows an organization to balance both short-term and long-term objectives, ensuring that progress is being made towards both immediate and ultimate goals. In this article, an operational excellence expert will discuss the importance of this approach and the steps organizations can take to implement it effectively.

The first step in setting annual objectives with 3 to 5 years breakthrough objectives is to define the long-term vision of the organization. This vision should reflect the organization's ultimate goals and should be ambitious yet achievable. It should also align with the organization's mission and values, as well as the larger goals of the industry or sector in which it operates.

Once the long-term vision has been defined, the organization can begin setting its annual objectives. These objectives should be specific, measurable, achievable, relevant, and time-bound (SMART). They should also align with the long-term vision of the organization. For example, if the long-term vision is to become the leader in a particular market, an annual objective might be to increase market share by a certain percentage each year.

The next step is to set the 3 to 5 years breakthrough objectives. These objectives should be significant milestones that are critical to achieving the long-term vision. They should also be challenging, yet achievable, and should align with the annual objectives. For example, if the long-term vision is to become the leader in a particular market, a 3 to 5 years breakthrough objective might be to become the market leader in a particular geographic region.

Once the objectives have been set, the organization can develop a policy to support their achievement. This policy should include specific strategies and initiatives that will help the organization achieve its objectives. For example, the policy might include initiatives to improve product quality, increase customer satisfaction, reduce costs, or increase market share.

In order to effectively implement the policy, the organization must allocate resources appropriately. This includes allocating both financial and human resources, as well as the time and energy of key stakeholders. The organization must also establish a process for monitoring progress towards the objectives and for making adjustments as needed.

The use of annual objectives with 3 to 5 years breakthrough objectives can be a powerful tool for organizations that are seeking to improve their performance and achieve their goals. However, it is important to remember that this approach requires a significant investment of time and resources, as well as a commitment to ongoing improvement. Organizations that are willing to make this investment will be well-positioned to achieve their goals and create a bright future for themselves and their stakeholders.

In a nutshell, the use of annual objectives with 3 to 5 years breakthrough objectives is a crucial aspect of policy development in an organization. It allows organizations to balance both short-term and long-term objectives, ensuring that progress is being made towards both immediate and ultimate goals. By following the steps outlined in this article, organizations can effectively implement this approach and achieve their goals.

Cell Production

Cell Production focuses on optimizing the flow of work and improving efficiency in manufacturing and operations. It is based on the concept of organizing work into cells, which are self-contained units responsible for performing a specific set of tasks. The goal of cell production is to minimize waste, increase flexibility, and improve overall performance.

The origins of cell production can be traced back to the 1950s and 60s, when Toyota and other Japanese companies were experimenting with new approaches to manufacturing. Over time, the concept of cell production has evolved and been refined, and today it is widely used in a variety of industries, including automotive, electronics, and consumer goods.

In order to implement cell production effectively, there are several key steps that organizations must take. Firstly, it is important to conduct a thorough analysis of the current state of the manufacturing or operations process, in order to identify areas where improvements can be made. This may involve mapping out the flow of work and identifying bottlenecks or other inefficiencies.

Once these areas have been identified, the next step is to reorganize the work into cells, taking into account the specific requirements of each cell and the skills and expertise of the employees who will be working in them. This may involve rearranging physical work spaces, or changing the way that work is assigned and managed.

It is also important to establish clear communication and feedback mechanisms, so that employees and teams can work together effectively. This may involve setting up regular meetings to discuss performance, or implementing systems for tracking and reporting on key metrics.

In order to ensure a successful implementation of cell production, it is also important to provide training and support for employees. This may involve providing training on the new processes and procedures, or offering coaching and mentoring to help employees develop the skills and knowledge they need to be effective.

Another key aspect of cell production is continuous improvement. This involves regularly reviewing performance and making adjustments as needed, in order to optimize efficiency and reduce waste. This may involve experimenting with different approaches, such as implementing new technologies or streamlining processes, in order to find the best solutions.

In conclusion, cell production is a powerful methodology for optimizing performance in operations and manufacturing. By reorganizing work into cells, minimizing waste, and continuously improving performance, organizations can increase efficiency, reduce costs, and improve overall performance. In order to be successful, organizations must take a structured and systematic approach, and be committed to ongoing improvement.

TPM - Total Productive Maintenance

Total Productive Maintenance (TPM) is a methodology that originated in Japan in the 1970s and has since become a widely recognized and adopted approach to operational excellence in manufacturing and other operations-focused industries. It is a comprehensive approach that seeks to optimize the performance of equipment and processes through a focus on maintaining and improving reliability and efficiency.

The origins of TPM can be traced back to the Japanese auto industry, where manufacturers were seeking ways to increase productivity and competitiveness in the face of increasing global competition. TPM emerged as a response to the need for a more proactive and integrated approach to equipment maintenance, with the goal of improving both productivity and overall equipment effectiveness (OEE).

Over time, TPM has evolved and expanded to encompass a wider range of objectives and activities. Today, it is widely regarded as a best-practice approach to operational excellence, and is widely used in many different industries, including manufacturing, healthcare, and government operations.

One of the key features of TPM is its focus on involving all employees in the maintenance and improvement process. This is achieved through the creation of cross-functional teams and the use of a range of techniques, including root cause analysis, standardization, and continuous improvement.

Another key aspect of TPM is its focus on data-driven decision-making and performance measurement. This involves the collection and analysis of data on equipment and process performance, which is then used to identify areas for improvement and to drive continuous improvement efforts.

When properly implemented, TPM can have a significant impact on organizational performance and competitiveness. This can include improvements in equipment reliability, increased productivity, reduced waste, and improved overall equipment effectiveness (OEE).

To achieve these benefits, it is important to implement TPM in a structured and systematic way, with clear goals and objectives and a strong focus on continuous improvement. This typically involves a multi-phased approach, starting with an assessment of existing processes and equipment, followed by the development of a comprehensive improvement plan and the implementation of specific improvement initiatives.

In a nutshell, TPM is a proven methodology that can help organizations achieve operational excellence by optimizing the performance of their equipment and processes. To achieve success, organizations must approach TPM in a systematic and structured way, with clear goals and objectives, and a strong focus on continuous improvement.

Key points for a successful TPM implementation:

1. Involve all employees in the process

2. Focus on data-driven decision-making

3. Adopt a multi-phased approach

4. Prioritize continuous improvement

5. Develop a comprehensive improvement plan.

Ringi Seido

The Ringi Seido methodology that originates from Japan is widely recognized as an effective method for achieving operational excellence. As an operational excellence expert, I can attest the benefits of implementing Ringi Seido in your organization.

Ringi Seido, which translates to "approval process," is a consensus-based decision-making system that involves different levels of an organization in the decision-making process. It is considered an essential element of Japanese business culture and has been widely adopted by Japanese companies for decades.

One of the key principles of Ringi Seido is involving all relevant stakeholders in the decision-making process. This includes front-line employees, middle management, and executives, allowing for a comprehensive and well-rounded approach to decision-making. The goal is to gain buy-in from all levels of the organization and ensure everyone is aligned with the company's vision and direction.

The Ringi Seido process begins with a proposal for a change or new initiative, which is then shared and discussed among the relevant stakeholders. Through a series of meetings and discussions, the proposal is refined and modified until it has the support of all relevant stakeholders.

One of the key benefits of the Ringi Seido process is that it ensures all necessary information is considered before a decision is made. This helps to reduce the risk of making decisions that are not in the best interests of the organization. Additionally, the process provides the opportunity for employees to voice their opinions and share their ideas, which can lead to the discovery of new and better ways of doing things.

Another benefit of Ringi Seido is that it promotes a culture of continuous improvement. The process encourages employees to regularly review and evaluate the implementation of the approved initiatives, which allows for the identification of areas that need improvement. This leads to a continuous cycle of improvement, as the organization continuously refines its processes and procedures to achieve better results.

One of the challenges of implementing Ringi Seido is that it can be time-consuming and require significant investment in training and development opportunities for employees. However, the benefits of the methodology make it a worthwhile investment, as it can lead to significant improvements in the efficiency and effectiveness of an organization's operations.

For organizations that are interested in implementing Ringi Seido, it is essential to have a clear understanding of the methodology and the specific steps involved in the approval process. This requires the participation of all relevant stakeholders and a commitment from the organization to provide the necessary resources, including training and development opportunities, to ensure the successful implementation of the methodology.

In a nutshell, I highly recommend the implementation of Ringi Seido for organizations looking to achieve operational excellence. While it may require a significant investment in time and resources, the benefits of the methodology make it a powerful tool for achieving better results. By involving all relevant stakeholders in the decision-making process, organizations can gain buy-in from all levels of the organization and ensure everyone is aligned with the company's vision and direction. This leads to a culture of continuous improvement, which is essential for achieving long-term success.

Implementation of 5S

If you want the short version just go here. Otherwise we will deep dive in this article on how to implement the 5S methodology in your organization. We will simply follow the 5 Steps and explain the topics.

1st S SEIRI = Sort out all unnecessary objects

• Unnecessary objects are all objects that are not needed for the current manufacturing processes (production, logistics, quality, and administration, etc.), that means, defective parts, unused material, material that has been written-off, all spare parts, non-utilized tables and so on

• Determine in advance, what is truly needed. This is helpful when dealing with statements such as: “That still can be used“, “That should be useful for something,“ etc.

• Remove all redundant objects or at least visually mark them so that everybody is aware that they are to be disposed of

• Unused objects should be concentrated in one marked closed area. The decision about those that can not be immediately liquidated, as whether to dispose of them, should be made by the person responsible within 2 weeks

Target: At the workplace are only objects essential for the current work in progress.

Red Tag Campaign

• Ask three questions for each separate object:

  • Is this object useful?

  • How many of these objects do we need?

  • Where should this object be stored?

• Don‘t support others in searching for excuses. Be fair – mark objects that should be removed in all divisions of the company

• Don‘t compromise! When in doubt - the rule applies: Get rid of it!

• If there are suggestions for improvement of the current manufacturing process, it is possible to “red tag“ even objects still in use

• Make sure that everybody understands what should be marked and why

Course of action and rules for the “Red Tag Campaign”

• Write on the tag why the marked object is not needed (Example: Surplus packing boxes; parts stored in boxes are not used any more)

• Contact Information about the person who made the decision that the object is superfluous (name and department)

• The person responsible for the object will be informed and their name will be entered on the “Red Tag”, and along with the agreed-upon date of removal (maximum 3 days), the action should be recorded (Example: The employee who recognized that the boxes are not used anymore, will inform the warehouse attendant and will appeal to him to verify if they are really not of use anymore. If it will be discovered that the object is still in use, the “Red Tag” will be removed. (For instance: The warehouse manager finds out that the boxes will be used to store other parts very soon)

• If the object will be classified among the superfluous, it must be removed within three days by the person who has the responsibility for this area. (For instance: Redundant storage boxes - person responsible for the warehouse). Afterwards the “Red Tag” can be liquidated

• Objects can be “Red Tagged” only in working areas of ones responsibility. The Shift Leader can issue “Red Tags” in the entire area they are responsible for

The “Red Tag” will be filled out by hand and attached to the unwanted object.

Examples of unwanted objects:

1 Defective products

• Faulty parts

• Rejects

2 Unnecessary objects

• Unused empty packaging

• Personal objects (on undefined places)

• Unneeded assembly sets

• Unused material (remaining bundles)

• Unused tools, auxiliary and production material

• Inventory no longer being used

• Surplus of manufactured components

2nd S SEITON = Clean-up and correct arrangement of needed objects

• After the removal of all unnecessary objects, remove all uncleanness, as new organization of areas for laying down objects or their storage can start only after everything is clean

• Each machine and each tool must have its designated place.

• Thoroughly deliberate about where you will store material, tools, and equipment

• Use colored markings (for instance stickers) to designate areas, cabinets, shelves, cupboards with shelves, important places, direction of work procedures, etc.

• With each object ask three key questions: Where? What? How many?

• Permanent storage of objects in

Targets:

• A place for each object and each object in its place

• Visual control and expedient detection of deviations

• Proper storage of all needed objects in the right place. These objects can then be found and used whenever needed

• Every thing has its own place and after its use is always returned to its place!

Think about color markings on the floor e.g.:

• Yellow = transportation zone

• White = raw material

• Green = finished goods

• Red = closed area/NOK parts

3rd S SEISO = Keeping the workplace tidy so as to achieve the already established standards through 5S

The purpose of the cleaning action is to remove all contamination from the workplace and to maintain it in order.

• For this purpose a cleaning schedule will be formulated that will determine what is to be cleaned, with what, and by whom

• If you discover any shortcomings or abnormalities during the cleaning process – mark them down

• All employees of the workplace / work area will participate in the cleaning process

• Keep records of the cleaning process, display visually “Red Tags,” as well as the clean-up time schedule of your workplace. Display results

• Define responsibilities with consideration even to the smallest work sections

• Be effective. Even a five-minute cleansing action can achieve a lot

Targets:

• Cleaner and safer workplace

• Achieving the already established standards

Cleanliness

• Cleanliness at the workplace must be observed, because a clean workplace is essential towards quality and safety at work

• If the workplace is not dirty it is not necessary to clean it

• Any kind of uncleanness and any kind of untidiness will be visible thanks to the initiation of a regular cleaning process – for instance, dusting, sweeping, and waste disposal

• Continuous usage of equipment

• Removal of all uncleanness and untidiness

• Prevention of working accidents

• Cleanliness means controlling, which implies that when cleaning a certain workplace, also check the state of the machinery, equipment, and working conditions

4th S SEIKETSU – Establishing regulations for work standards

SEIKETSU has the greatest importance of all 5S Steps.

• With this 5S Step the main focus is on three aspects:

1. No unnecessary objects

2. No messiness and

3. No uncleanliness

• Visual control is the first step towards discipline. The ideal workplace is that with which any eventual problems can be detected at first glance – any corrective measures can be immediately implemented

• Use control lists to control the 5S standard and to identify deviations from the defined 5S standards

• Conduct 5S audits with consideration to the situation on the individual work place. Attempt to identify deviations from the 5S standards

• Ask yourself “follow-up questions”, as for instance: Has the mess been cleaned up immediately? Is it clear who is supposed to do the job? Can the clean-up be done quickly? - and others

Targets:

• Securing the adherence to the 5S Standards

• Increasing the team responsibility on the work place

• Schedule of everyday clean-up

5th S SHITSUKE – Adherence to the Work standards and continuous improvement

• Discipline, namely, adherence to work standards is basically a question of personal attitude. For it to be easier, various teaching aids are used, e.g. Courses of the 5S Basics

• Use photographs, single-topic lectures, video-programs and presentations

• Constructive criticism is the foundation for proper 5S training

• Take pictures to document the status quo before and after

• The Team Leader functions as an example to the team. During his work he should focus on the goals of 5S, he should strive for a continuous improvement of quality and in this direction aim his training activity also

• Define together the measures for improvement and how to realize them.

• Regulations are better than criticism and a system is better than regulations

Targets:

• Promotion of this know-how in the entire company from top-to-bottom

• Well-organized work places that require only the minimum attention