Prepared by: Obaid Bilgarami

Manager Coordination
• The most Pragmatic, Down-To-Earth and
Process Oriented Manufacturing Approaches.
• More focused on Process Improvement
(New Manufacturing Vision).
• Effective Efficiency Optimizing Approach
(Not Efficiency Maximizing Approach).
• Stepping stone top other manufacturing
standards, i-e; Lean, ISO 9000, TS 16949,
etc.
• Kaizen • Kanban/Pull System
• 5S. • Muda, Mura, Muri
• Gemba • Heijunka
• Genchi Genbutsu • FIFO
• Obeya • Takt Time
• Poka Yoke
• Jidoka
• Andon
• A combination of two Japanese words:
Kai = Change & Zen = Better
i-e;
Change for Better
• Kaizen Cycle (Good Better Best)
• Kaizen Mind
• Kaizen Procedure
• Before/ After Approach
• Seiri (Sorting)
• Seiton (Setting)
• Seiso (Sweeping)
• Seiketsu (Standardizing)
• Shitsuke (Sustaining)
• The word literally means ‘The Place where
truth can be found’ and refers to ‘The Place
Where the Activity is happening like Crime
Scene, Play Ground, Production Floor, etc.’.

• The availability of Incharges, i-e;

Production, QC, Maintenance at floor to
ensure system effectiveness and Factual
Analysis of Problem if occurs.
• The word literally means ‘Go See for
yourself’ referring to the Gemba Attitude, i-
e; instead of depending on hearsay,
reports, summary charts, or any docs, get
out and visit the place where actually the
problem occurs.

• This attitude enables an effective and

most appropriate decisions based on ‘On
the Spot Analysis’.
• The word literally means ‘Big Room’ and
refers to ‘The room where reports/ results/
Summaries & Performances are displayed
for Management Perusal.

• The Management holds meeting to

evaluate the Deptt. Performance/Issues,
Activities Status and propose rational
decisions.
• The word literally means ‘Mistake Proof’
and refers to ‘Any device, limits or system
installed at operations to ensure zero
defect/ error/ mistake’.

• The Zero Defect Target can only be

achieved if the abnormality is stopped at its
place of origin, this is what poka yoke for.
• The word literally means ‘Automation or
Intelligent System’ and refers to ‘Machine
to be built/added with devices or limit
sensors to stop in case of an abnormality’.

• This system is to ensure fast, effective

and reliable means of production to
eliminate inadvertent errors, negligence,
maintenance failure like Poka Yoke.
• The word literally means ‘Paper Lantern’
and refers to ‘status-display station or a
system to notify management,
maintenance, and other workers of a quality
or process problem’.

• This is another example of Jidoka to

eliminate the error/ defect at it’s place of
origin with Problem Identification at
machines
• The word literally means ‘Visual Card’ and
refers to ‘Kanban is a signaling system to
trigger action. In kanban, cards are used to
signal the need for an item from Inventory
Stock or suppliers ’.

• It is based on ‘Pull System’ and also refers

to JIT System which is another hallmark of
Japanese Manufacturing System.
• The word literally means ‘Level’ and
refers to a system of production
smoothing/ leveling designed to achieve a
more even and consistent flow of work ’.

• It is based on study of processes

sequence and their flow on machines to
implement best possible line balancing, i-
e; also called Chain Production.
• Muda (Waste)
1. Over-production
2. Motion (of operator or machine)
3. Waiting (of operator or machine)
4. Conveyance
5. Processing itself
6. Inventory
7. Correction (rework)

• Muri (Overburden)
• Mura (Inconsistency)
• The German word literally means ‘Clock’
and refers maximum time allowed to
produce a product ’.
• Takt Time is defined as:
T= Ta/Td
Where:
Ta = Net Available Time to Work eg. [minutes of
work / day]
Td = Total demand (Customer Demand) eg. [units
produced / day]
T = TAKT Time eg. [minutes of work / unit produced]
• It stands for ‘First In First Out’ and refers
to the inventory system where what comes
in first is handled first, what comes in next
waits until the first is finished ’.

• An effective way of Inventory Management

to ensure smooth flow of inventory with date
wise traceability to avoid stock from
deterioration and going abnormally excess
and also en effective tool of JIT/Pull System.
• Kaizen = Change for Better
• 5S. = Work Discipline
• Gemba = Activity Place
• Genchi Genbutsu = Go & See The Problem
• Obeya = Monitoring Room
• Poka Yoke = Mistake Proofing
• Jidoka = Automization
• Andon = Visual Control
• Kanban/Pull System = Signal for Production
• Muda, Mura, Muri = Waste/Unevenness/Overburden
• Heijunka = Line Balancing
• FIFO = First In First Out
• Takt Time = Production Time
• Japanese Management Tools begins with
simple Kaizens and results into an Industry
with Work Inducing Environment, Optimally
Effective Production with Zero Defect Ratio
and Efficient Utilization of Machines &
Manpower and ultimately with continual
upward trend of profitability and downward
trend of losses.
Thank You