e-Kaizen Solutions - www.tpm-us.

com

Cultivating for Proactive Philosophy

World-Class Manufacturing Excellence e-Kaizen Solutions by PM Systems Corporation

Shinichi Shinotsuka
Kaizen Consultant www.tpm-us.com info@tpm-us.com

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

Shinichi Shinotsuka, e-Kaizen Consultant

www.tpm-us.com / info@tpm-us.com 1023 Muirfield Drive Marietta, Georgia 30068 USA Phone 770-575-1934 Fax 770-578-9784

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

Never do things by halves

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2003-2007 by PM Systems Corporation

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

Total Process Management

Strategy (Where we are going)

Performance Evaluation (Indicators)

Information Develop Make Sell Customer

Rotate this Cycle (Develop-Make-Sell) quickly

Level-1 Level-2 Level-3

Leadership
Managerial Organization
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2003-2007 by PM Systems Corporation

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

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
How will managerial organization change? 9Managers role 9Supervisors role & Operators role

What indicators should we focus? 9Data Collection & Reporting systems 9Goal-sharing system 9Progress monitoring & follow up

What milestones should we setup? 9Pillars 9Connect with Corporate Strategy & Goal

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2003-2007 by PM Systems Corporation

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

e-Kaizen Solutions Zero losses in Manufacturing System

e-Kaizen Process Scorecard Leadership
Steering Committee Goal Sharing Step Diagnosis + Top Diagnosis Progress Control Kaizen/TPM Facilitators Overlapping Small Group Daily Management

8 Pillars Deployment
Autonomous Maintenance Planned Maintenance Focused Improvement Training & Education Early Management Quality Assurance & Maintenance Administrative operations Kaizen Safety & Environment Total Productive Maintenance

Performance Review
Kaizen/TPM KPI P-Q-C-D-S-M Daily Data + Monthly Summary Benchmark (Baseline) Data Cascade Trend Control Zero-Oriented Target

Total Perfect Manufacturing

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2003-2007 by PM Systems Corporation

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

e-Kaizen Workshop Process Flow Chart

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 Facilitator e-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

Workshop Design Meeting (On-Site / Off-Site)

< 1 week Workshop Fee Estimation

1 Day On-Site Workshop Preparation

4 6 Weeks Workshop Host Plant

e-Kaizen Workshop
1-2 Weeks Summary & Review Report

e-Kaizen - Workshop Course Agenda

e-Kaizen Workshop Review

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2003-2007 by PM Systems Corporation

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

(S) Start-up Course (Basic)

1st Day 2nd Day 1st Day Review 5S & Safety Team Presentation AM Step-1 3rd Day 2nd Day Review AM Step-1 Team Presentation Focused Improvement (Break) 5S & Safety Team Practice (1) Hands-On Practice (1) 5S & Safety 5S Board Preparation Close Planned Maintenance FI CAP-Do Cycle Final Presentation 4th Day 3rd Day Review FI CAP-Do Presentation Training&Education

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

8:30 8:40 9:00 10:00 11:00 11:20 12:30 13:25 14:00 17:30 18:00 21:30

8:40 9:00 10:00 11:00 11:20 12:30 13:25 13:55 17:30 18:00 21:30

Registration Course Overview Team Building Practice Kaizen/TPM Overview

Lunch Team Practice (2) Team Practice (3) Hands-On Practice (2) Hands-On Practice (3) AM Step-1 FI CAP-Do (Break) AM-1 Board Presentation FI CAP-Do Board Close Close

Preparation Materials 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 Presentation 4 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

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2003-2007 by PM Systems Corporation

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

(F-1) Basic Facilitator

Kickoff for World Class Manufacturing Excellence Trainers Training Roadmap
Caution
In preparation stage, Train every Manager, Supervisor, Team Leaders To Create Kaizen Trainer.

PM for Zero Breakdowns 3 Days

Start-up Course 4 Days Basic

e-Kaizen Pre-Consulting Meeting

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2003-2007 by PM Systems Corporation

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

PM (Planned Maintenance) Workshop

Who attend; Maintenance Supervisor Kaizen Trainers* - who attended (S) Start Up Course What; Learn Kaizen Basic PM 8-Element Approach Logical Root-Cause Analysis 5S & Visual Control Data Analysis When; 2 Days Where; Host Plant How; On-Site Practice Fee; $2200 per day + Training Materials
Preparation Materials 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 3-3 Yellow (Safety) - 500 4) OPLs - 500 5) Card Board for Presentation 4 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 1st Day 8:30 8:40 9:00 10:00 11:00 11:20 12:30 13:25 14:00 17:30 18:00 21:30 8:40 9:00 10:00 11:00 11:20 12:30 13:25 13:55 17:30 18:00 21:30 Logical Root-Cause Analysis Breakdown Analysis Registration Course Overview Team Building Practice Planned Maintenance Overview 2nd Day 1st Day Review Team Presentation 5S (Spare Part & PM Workshop) (Break) 5S Spare Part Room & Workshop Lunch Team Practice (1) Hands-On Practice (1) Breakdown Analysis (Break) Presentation Board Close Team Practice (2) Final Presentation (14:30 - 16:00) PM

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2003-2007 by PM Systems Corporation

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

Quality Pillar Workshop QM 10 Step Deployment

1st Day 2nd Day 1st Day Review Step-5 & 6 CAP-Do Cycle QM 10 Step Deployment Step-7 To Step-10 (Break) QM 10 Step Deployment Step-1 To Step-6 Lunch Team Practice (1) Hands-On Practice (1) Step-1 To Step-4 (Break) Logical Root-Cause Analysis Close Team Practice (2) Final Presentation (14:30 - 16:00) QM 10 Step Deployment Step-7 To Step-10

Who attend; Quality Supervisor & Leaders Process Engineers Kaizen Trainers* - who attended (S) Start Up Course What; Learn Kaizen Basic Quality Assurance & Maintenance QA & QM Matrix QM 10 Step Deployment Data Analysis When; 2 Days Where; Host Plant How; On-Site Practice Fee; $2200 per day + Training Materials

8:30 8:40 9:00 10:00 11:00 11:20 12:30 13:25 14:00 17:30 18:00 21:30

8:40 9:00 10:00 11:00 11:20 12:30 13:25 13:55 17:30 18:00 21:30

Registration Course Overview Team Building Practice Quality Pillar Overview

Preparation Materials 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 3-3 Yellow (Safety) - 500 4) OPLs - 500 5) Card Board for Presentation 4 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

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2003-2007 by PM Systems Corporation

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

e-Kaizen - Coaching & Workshop Milestone

Awareness Confusion Understanding Interest Fun

Preparation 6-12 months

Pre-Consulting Visit

Expansion 12 months Kickoff

Implementation 12 months

Consolidation > 12 months

Leadership Start-up Course

Machine changes
QM 10 Step Deployment RFT-Changeover
Right First Time

Mindset changes
Autonomous Maintenance Step-4 General Inspection Preparations

PM for Zero Breakdowns

zBe fun with Kaizen! e-Kaizen Kaizen Consultant

Early Equipment Management M-P Database & Design Review

General Inspection 100 % Operators Initial Clean

Managers & Team leaders

AM Standard SOCS & HTA

zThrough sharing many good examples, Operators are familiar with a Team Working and zDevelop Zero Case Studies

zThrough many case studies to eliminate SOCS, Operators take interest in Kaizens and 100 % employee can use Basic Kaizen Tools (Methodology)

Instructors & Facilitators Training

zThrough cleaning up every piece of component in equipment, People understand how machine works correctly

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2003-2007 by PM Systems Corporation

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

The Basic Concept of e-Kaizen

Number of Equipment Breakdowns Trend - Example
Number

10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 0
ar k M m

Improve

Maintain

Prevent Recurrence

Prevent Problems

Be nc h

on th 12 m on th 18 m on th 24 m on th 30 m on th 31 m on th 32 m on th 33 m on th
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2003-2007 by PM Systems Corporation