Kamishibai

Introduction to Kamishibai
AGENDA:
# What is Kamishibai?
# Layered Audit Basics
# Kamishibai Process & Board Layout
# Audit Plan & Process
 Introduction to Kamishibai

What is Kamishibai?
In Japan: story-telling for
entertainment and children’s
education Japanese for “paper
drama”
 Introduction to Kamishibai
A simple and visual card system used for layered auditing of:
• Safety
• Quality (Product and Process)
• 5S
• Inventory Management
Brings all levels of the organization to Gemba
Layered auditing establishes accountability from the top-down
 • What are Layered Audits?
• An objective evaluation of how we are
performing
in specific areas where standards,
policies, or requirements have been
defined
Layered Audit • Provide real time feedback that
promotes visibility and action
Basics • Promote team focus, engagement, and
sustainment efforts
• “Layered,” because everyone,
including associates, production
support, managers and senior
leadership, is responsible for
participating in the audit
 • Why Layered Audits?
• Validates whether we are doing
what we said we were going to do
(“inspect what you expect”)
• Identify continuous improvement
Layered Audit opportunities in training,
Basics equipment, processes, and safety
• Align expectations throughout the
organization
• Critical to the foundation and
sustainment of our safety, quality,
and inventory processes
 • When and How are they conducted?
• Performed daily, weekly, bi-weekly
and monthly depending on your
role within the organization
Layered Audit • Dynamic: Specific activities being
audited may change regularly, as
Basics improvements are made
and new opportunities are
identified
• Requires countermeasures for non-
conformance (just do it!)
Kamishibai Process
• Kamishibai connects layered
auditing with visual management
• At a glance view of audit
findings, actions, and owners
• Reviewed at Daily Management
• Identifies real-time systemic
issues (process breakdowns)
• Ensures audits are being
performed per plan
 • Deck of cards to be audited

• Completed pass/fail cards

Kamishibai • Coverage of audit board

Board Layout • Audit plan & schedule

• Pareto analysis

• Issue/Countermeasure sheet
 RESULT – KAMISHIBAI BOARD
Layout

Process Flow

Audit
Schedule

Pareto by
Card

Pareto by
Area

Card Holder Card Box RCCM

Example Assembly Kamishibai Card Assembly Kamishibai Card
Safety Card # 7 Safety Card # 7
Kamishibai All Fire Extinguishers have been A Fire Extinguisher does not
Cards inspected, up-to-date, and have proper proof of
signed. inspection/functionality.

Improperly functioning fire extinguishers may Improperly functioning fire extinguishers may
Why: cause unnecessary safety incidents in the Why: cause unnecessary safety incidents in the
event of a fire. event of a fire.

Front Back
Example Assembly Kamishibai Card Assembly Kamishibai Card
Safety Card # 12 Safety Card # 12
Kamishibai All employees on the Employees on the
Cards Manufacturing floor are Manufacturing Floor are
protected with safety glasses missing side shields or other
and/or side shields. proper eye protection.

Safety glasses are critical to Safety glasses are critical to

Why: helping prevent eye injuries. Why: helping prevent eye injuries.
Example Assembly Kamishibai Card Assembly Kamishibai Card
Quality Card # 1 Quality Card # 1
Kamishibai
Calibration due date of tool is Calibration due date is in the
Cards later than current date past

Tools not measuring properly could Tools not measuring properly could
Why: lead to quality defects
Why: lead to quality defects
 Assembly Kamishibai Card Assembly Kamishibai Card
Example Quality Card # 25 Quality Card # 25
Kamishibai Chemicals in the area are not Chemicals have expired
Cards expired

Chemical may not perform to Chemical may not perform to

Why: specification beyond expiration Why: specification beyond expiration
date. date.
 Assembly Kamishibai Card Assembly Kamishibai Card
Example Safety Card # 4 Safety Card # 4
Kamishibai Clear path to all Fire Path to any Fire Extinguisher
Cards Extinguishers has been impeded or blocked

Blocked or impeded access to the Blocked or impeded access to the

Why: fire extinguishers could pose safety Why: fire extinguishers could pose safety
issues in the event of an emergency. issues in the event of an emergency.
 Assembly Kamishibai Card Assembly Kamishibai Card
Example Inventory Card # 19 Inventory Card # 19
Kamishibai Kanban card quantity matches Kanban card quantity does not
Cards quantity in bin 2 of 2 and Stop Sign is
present
match quantity in bin 2 of 2 and
Stop Sign is present

Incorrect material quantity in bin 2 of Incorrect material quantity in bin 2 of

Why: 2 can cause stockouts and late Why: 2 can cause stockouts and late
shipments shipments
 Assembly Kamishibai Card Assembly Kamishibai Card
Example Quality Card # 6 Quality Card # 6
Kamishibai
Kamishibai audit plan is up to Kamishibai audit plan is
Cards date for each auditor incomplete or past due for
one or more auditors

Audits must be performed regularly at all Audits must be performed regularly at all
Why: levels of the organization to ensure proper Why: levels of the organization to ensure proper
accountability and continuous improvement. accountability and continuous improvement.
 Kamishibai Board Layout

• Deck of cards to be audited

• Completed pass/fail cards
• Coverage of board
• Audit plan & schedule
• Pareto analysis
• Issue/Countermeasure sheet
 Audit Plan
Role Auditor Name Week 1 Week 2 Week 3 Week 4

CELL ASSOCIATE

CELL ASSOCIATE

CELL ASSOCIATE

CELL ASSOCIATE

CELL ASSOCIATE

VP/GM Dover Motion

DIRECTOR OF OP.

MFG. MANAGER

QUALITY MANG.

QUALITY MFG ENG.

EHS

OPTIONAL AUDIT

OPTIONAL AUDIT

OPTIONAL AUDIT
 Audit Plan

Doc No. GVRI/KAM/EOU-02

Doc Rev No. 1
KAMISHIBAI AUDIT TRACKING SHEET - METER Preared by M.Ammaiyappan
Approved by S.Rajkumar

Month : April 18
Role Auditor Name Daily Weekly Bi-Weekly Monthly Quarterly
1.DINESHKUMAR
Quality Inspector 2.EASWARA MOORTHY
3.IWIN

Production Supervisor R.THASARATHAN

Quality Supervisor V.MANIKANDAN

Production Manager K.PRABU

Quality Manager B.RAGURAMAN

Production Head S.VIJAYKUMAR

Quality Head S.RAJKUMAR

Operations Head T.M.JEYAKUMAR

 LESSONS LEARNT

➢ Team work is very crucial for success of Kaizen

➢ Importance of detailed Layout

➢ Kamishibai Process and linkage with DM

➢ CFT approach is key of success

➢ Importance of 5S, Safety and Quality

➢ Importance of sustenance of actions for growth and success of Organization

Audit Process

“Pass” Audit:
Audit Process

“Fail” Audit:
Audit Process

• Additionally, if the audit fails, the auditor fills in the pareto

charts by cell (card number) and card number (date)
Audit Process
• Deck of cards to be audited
• Completed pass/fail cards
• Coverage of board
• Audit plan & schedule
• Pareto analysis
• Issue/Countermeasure sheet
Process Flow
Chart
Thankyou