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Lean Management

Assignment 1

Kamishibai Boards

Submitted by:
Prasahnt Arora(119278111) Pooja Pant(119278042) Kartik Dua(119278010) Mahak Garg (119278096)

1. In the context of Lean what is a Kamishibai Board? It is randomized and also scheduled audits of processes checks and standards which helps to find out of the process abnormalities and the reason for the same. Mostly this this tool s more usefeul when practice of genchi gonbutsu is followed. This visual tool helps managers to formalize and schedule the checks to be made and to ensure that they are completed. Kamishibai system focusses more on the cause of the problem to promote improvements and less the person responsible for causing the problem. Problems are identified when they are still small and hence aids as a lesson to everyone. The purpose is not to find faults, although problems should certainly be made visible; the purpose is to get in the habit of checking each day. Using Kamishibai: Kamishibai board is equipped with cards for various standardized processes in the system. The team leader/manager picks out a card randomly from the board. He/She reads the instructions for the corresponding timely check and goes to that process to perform the check. This time could be month , week or day depending the requirement. Once the check has been carried out, the card is returned. In case of abnormalities, and the card is turned over and kept back on the board indicating a problem in the system. This two-color system is used for visual indication of problem areas. The respective leaders/mangers take find finds out the reason, takes corrective actions. The kamishibai process for the team leader, group leaders, area managers and above differs slightly. All of them have different span of audit .Moreover the timing of the cards and checks are based on their schedules. 2. What are the advantages of using it in a Lean transformation? Please give examples. Note: marks will be given for original and imaginative examples not found in textbooks.

If a kamishibai audit results in the discovery of many non-conformities, this is a sign that the process is unstable or that one of the either of man, material, machine or method is too variable in the workplace. it is a tool for maintaining a stable, reliable, high performance system. These audits are essential to ensure the system (TPS) is functioning per Standard Work. In the machining environment it helps in checking vital specification to ensure stability & variation of the machining application. Day-To-day example of Kamishibai: Preventive Maintenance system of machines is an example of Kamishibai where the personnels check for the regular functioning of the system and takes the measures in case of abnormalities Regular visits of the doctor to the patients in the hospital is an example of kamishibai system . Though this system is not random, the technique followed is similar. The

doctor checks the reports, diagnoses the patient and if the system is not working as expected he recommends the treatment. In the process doctors also makes recommendation such that, in future such disorders are avoided. The reports work as a sort of cards where doctors can mention the abnormality in the patient ( if any). Principals going for random audits in School to find out if the classes are conducted in the prescribed manner. In case they are not, reasons are analyzed to find out why not and corrective measures are taken (like improper scheduling of teachers etc.) to bring the system in line.

3. Where would you use these boards? Kamishibai boards must be used in places where we want to ensure that standard work practices are followed to a great effect, which should then create habits and drive behavior. It is essential in processes which require regular audits, for example in daily cleaning and maintenance of toilets and bathrooms in hostels, sorting and grouping of mails/letters of inmates of a hostel or a hotel into different wings or floors, to ensure pickup and delivery in a fast food restaurant, etc. Apart from the normal periodic audits, Kamishibai boards can lead to an effective dialogue between members of management and the operators. This dialogue is critical to the success of lean implementations. In their periodic discussion and audits, a manager and an operator might just stumble upon a great idea which can then be documented on the back of their card for future implementation, if possible. 4. What could go wrong with their use and what steps would you take to avoid this?

The use of Kamishibai Boards as audit systems requires a lot of discipline from every employee of the organization right from babuji to the management. The process of auditing can go horribly wrong in two scenarios If the cards are turned from red to green without completing the work The cards are not turned to complete even after completion of the work

Both these scenarios are sure to create immense confusion among the employees of the organization and will definitely hamper the process. It will increase the workload rather than streamlining it. This is not in line with the lean ideology. Kamishibai Boards focus the attention of the management on the gemba. The managers need to be serious with the application of the Kamishibai Boards. They need to take time out to make the trip to the Kamishibai Board. Only then will the purpose and advantages of Kamishibai Boards will
be achieved.