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04/03/2010

Yamazumi Boards

Yamazumi Boards

Yamazumi Chart - Example

Yamazumi Boards
Yamazumi Charts are typically found in Japanese factories that use the lean production concepts made famous by the Toyota Production System. This hub shows how you can create Yamazumi charts to improve any process in your home or office. So what is a Yamazumi chart? Think of it as a revolutionary, visual method of identifying the roadblocks in a business process. This example shows a simple printing process at a copy shop. A Yamazumi board is just a stacked bar chart. In Japanese, the word "Yamazumi" literally means "to stack up". The business process starts at the base of the column, and each block is shown by minutes taken. The aim is to show operator and process cycle times. 1. The steps that are necessary to the process but do not really "add value" are in or an ge. 2. The steps that make a real difference - the execution steps - are in gr een. 3. The waste in the process - the blockage or failure mode - is in red. In this example the problem is a breakdown in the printing machine that requires time and energy to fix. These are the failures that must be eliminated through such lean production techniques as kaizen (continuous improvement) and p oka-yoke (simple but effective) solutions. For more advanced business problems Six Sigma thinking can be used to analyse the root causes of problems using the celebrated DMAIC (Define - Measure - Analyse - Improve Control) methodology.

The Five Advantages of Yamazumi Boards
1. It's visu al. If a picture is worth a thousand words, it's worth a hundred thousand figures. With Yamazumi charts (also known as Yamazumi boards as they literally are signboards in the "visual factory"), workers can immediately and intuitively see where the delays are coming from. 2. It's simple. Clarity is power. Who needs a management consultant's detailed report, when a Yamazumi Board tells the story at a single glance.

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g. You can read the full story in "The Machine That Changed The World" by Womack. This innocent little stacked bar charts can turbocharge your life. but it might be just as eye-opening for you as it was for the workers on the Toyota line when they first implemented the lean production strategies that became globally famous as the Toyota Production System. (c) WestOcean 2009 hubpages. (1) In the office Take any task in the office which is burdensome and complex. could . a few tweaks to the production line. hour by hour. Hanging above the production line. It's public. Remember the philosophical concept of Occam's razor? This arose from the wise words of 14th century English physician William of Ockham. Look out for the "hidden factory" of re-work. And the sheer amount of time spent on non-value added activities (watching TV) or maintenance activities (sleeping. glaringly so. you can see visually where the key constraints. Inputs drive outputs. eating) is astounding. The Yamazumi Board is in the open. you will find. He argued that "entities should not be multiplied unecessarily".com/hub/Yamazumi-Boards 2/2 . execution time that adds value and blockages or delays that slow the process. With a Yamazumi Board.change your life.if they are consistently maintained . 20% of all causes account for 80% of results. perpetual exhortation to continuous improvement. The Yamazumi board proves that simplicity really is power. This one can't go straight to the "circular file". The Yamazumi Board. or Kaizen. You realise after a time that just a few modifications. Then map your Yamazumi chart. This can be done in a simple spreadsheet. Regardless of its nature. With competitive work teams. It's inescapable. Nothing motivates better than public disclosure of results among colleagues. 5. How can you improve your process to make the bar as green as possible. Jones and Roos. Yamazumi Your Life! Are the Yamazumi Boards only useful if you work in a Japanese car factory? Think again. Yamazumi Your Life Yamazumi Your Life! Applies business strategies to revolutionise your life.some actions yield more fruit than others. It pinpoints the vital few op por tunities that can change everything. a few key inputs yield impressive outputs. Remember the Pareto Principle. meaning that the simplest theory solution is usually the best. this is a great motivator to positive performance improvement. and you should focus on the inputs to deliver better outputs. Magnify the power of your process by focusing on the "vital few". Why should lean production only be used in factories when the same concepts can help you in your daily life. Even the green activities may be sub-optimal. This is a key Six Sigma principle as the Y=f(x) methodology explains. This represents the COPQ (cost of poor quality) in the process which is rarely evaluated or calculated correctly because it is often not measured. the key roadblocks are. A Yamazumi board will help you find it. This may seem an odd exercise. As the Pareto principle suggests. and shorten the cycle time? (2) Th e Whole Life Yamazumi I challenge you to map your entire life as a Yamazumi Chart for an entire week. First. every business process will have three features . It may be anything from cutting code or drafting legal documents. because there is opportunity cost . 4. Draw up a simple Yamazumi for your chosen process.04/03/2010 Yamazumi Boards 3. "lunch" or "gym" and assign a colour to the chunk of this time. to see where the real value is. so just give your time buckets a quick summary e. has real power. break your week down into seven columns of 24 hours.preparation time. This isn't intended as an exercise in creating unnecessary work. the Yamazumi Board is a constant. Lunch would be Yellow because it is a maintenance rather than a "value add" function.