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Operations Management Consulting Division

17 STEPS
To Run

TPS - JISHUKEN

Operations Management Consulting Division

STEP - 1

1. Patrol Check base on STOP 6 ( by Jishuken Team ) 2. Making Rank Criteria ( Company Management ) 3. Confirm Actual Patrol Check ( Company Decision )

SAFETY ASSURANCE

4. Company Decision ( Rank Category ) 5. 4M analysis ( Control item & Control Point ) 6. Countermeasure for Safety Assurance ( Permanent & temporary base on 4M ) 7. Company Standardization ( Safety Rule, Guidance, SOP, etc )

Operations Management Consulting Division

STEP - 2

8. Data Collection 9. Discuss with Supplier

THEME SELECTION

10. Theme Selection

Operations Management Consulting Division

STEP - 3

11. Make Process Flow Table 12. Draw PFC

MAKE PART FLOW CHART (PFC) BEFORE

Operations Management Consulting Division

STEP - 4

13. Check Machine Loading Capacity 14. Set Up Fix Part on Each Machine
( Temporary Standard for Material & Machine )

ARRANGE SMOOTH FLOW (SEIRYUKA)

15. Set Up PFC Target Image


16. Arrange Smooth Flow

Operations Management Consulting Division

STEP - 5

17. Training & Simulation Game 18. Make Store 19. Make Temporary Standard (by 4M analyze) 20. Keep Temporary Standard 21. Trial

SET TEMPORARY STANDARD

Operations Management Consulting Division

STEP - 6

CONFIRMATION TRIAL

22. Confirm implementation from PUSH to PULL system for several days (maximum 1 week trial)

Change information issue method Use Internal Kanban Temporary

Current stagnation condition

Operations Management Consulting Division

STEP - 7

23. Add Information Flow on PFC 24. Grasp Current Condition/Information (5W 2H) 25. Lead Time Calculation
(Before means that the condition was after setting temporary standard )

MAKE
PART & INFORMATION FLOW CHART (PIFC)

BEFORE

Operations Management Consulting Division

STEP - 8

26. Draw PIFC without any Stagnation on Part & Information 27. Lead Time Calculation

MAKE
PART & INFORMATION FLOW CHART (PIFC)

IDEAL

Operations Management Consulting Division

STEP - 9

28. To Compare Before and Ideal Condition 29. List Up Gap/Problem

GAP / PROBLEM

ANALYSIS

30. Setting Priority of Problem to be Improved 31. Problem analysis by 4M

Operations Management Consulting Division

STEP - 10

32. Decide Kaizen Direction base on priority For Each Process 33. Set Up Target Condition
Decide Control Point for : 1. Process Performance Target 2. Result Performance Target

SET UP
JISHUKEN TARGET

Operations Management Consulting Division

STEP - 11

34. Draw PIFC Target 35. Decide What Supporting Tools Should be Made 36. Lead Time Calculation Base on Target 37. Get Suppliers Top Management Commitment

MAKE
PART & INFORMATION FLOW CHART (PIFC)

TARGET

Operations Management Consulting Division

STEP - 12

38. Decide Group Base on Necessity Kaizen To Be Done


( Set Role & Responsibility of Each Member )

SET
JISHUKEN GROUP & SCHEDULE

39. Decide Daily Schedule Activity & Follow Up System


( Periodic Discussion with Suppliers Top Management )

Operations Management Consulting Division

STEP - 13

40. Nemawasi to Related Shop Floor to Get Request & Support


(Self Introduction, explain the purpose & ask for request)

KAIZEN ACTIVITY

41. Data Processing & Temporary Tools Making 42. Self Simulation 43. Formal Tool Making 44. Make Standardized Work, Supervisory Role & Abnormality Rule

Operations Management Consulting Division

STEP - 14

45. Conduct Training to Related Operator / Leader 46. Trial New System

TRAINING & TRIAL

47. Monitoring & Follow Up (Using Check Sheet)

Operations Management Consulting Division

STEP - 15

48. Analize Actual Result vs Target / Standard


-Check Fluctuation of Actual with Standard for each Control Point -Run This Step for Several Times -Check Operator Walking, Motion & Feeling (eyesight, hearing, Touch, smell, etc )

TRIAL RESULT EVALUATION

Operations Management Consulting Division

STEP - 16

49. Make Visualization Control for 4M 50. Set Supervisory Role

MAKE
STANDARDIZED WORK

51. Daily Maintenance by Management refer to Decided Control Point

Operations Management Consulting Division

STEP - 17

52. Suggest Kaizen Recommendation to Supplier for Level Up Activity 53. Continue Remaining Kaizen

SET
NEXT STEP KAIZEN TARGET