Foremen's Activities: Cost-Reduction Examples from the TAM Manual. .. This process is called Policy Deployment, or in Japanese, hoshin kanri. First, top . GEMBA KANRI PDF - Genba is a Japanese term meaning "the actual place". Japanese Downloads: Price: Free* Why 'genba kanri'; why 'kaizen'?. Gemba (+4-Min MP3, +6-Page PDF) In fact, there's another Japanese term for this: genba kanri—which means . Lean Terms Downloads.

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Download full-text PDF .. The fifth principle of lean leadership is hoshin kanri, in development or hoshin kanri and how important these. PDF | Manufacturing organizations have used Lean management principles for Download full-text PDF . proofing), and hoshin kanri (ie, a strategic plan-. improvement culture, self-development, qualification, gemba, and hoshin kanri. These requirements shall help executives in realizing lean leadership.

Following the value chain will give you the best opportunities to identify areas with a high potential of waste activities. Eliminating those activities will help you improve the overall performance.

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Record your observations. Write down everything that grabs your attention or even record it with your smartphone. In some cases, you will probably be tempted to offer a solution immediately, but this would be wrong. Leave the analysis for later. You will be much more precise after you have all the facts available.

Furthermore, the broad overview can offer you opportunities to use effective problem-solving tools such as PDCA cycle. Much better than an instant gut feeling. An extra pair of eyes. It may be a good idea to invite a colleague from another department. Someone with totally different daily tasks. People who are less familiar with the processes usually have a fresh point of view and ask different questions that you may never ask. Otherwise, the team will only have the feeling of being watched.

If you are going to take actions after the walk, inform the team about the upcoming changes and why they are necessary. Gemba Walk Checklist Every time when you perform a Gemba walk, you need to prepare a checklist in advance.

This list will help you focus and target your efforts. The checklist has to include questions that will help you understand the process you are going to observe in a better way.

Your questions may vary depending on the theme of your Gemba walk.

Here are some basic Gemba walk checklist questions: These questions will defer when exploring different areas such as: problem-solving, innovation, resources, tools and etc. So before you go Gemba, prepare your checklist carefully based on the area you want to investigate. Post-Gemba Walk Before you take any actions based on your Gemba walk observations, you will need some time to organize your thoughts and notes.

Feedback is important, but early feedback may be devastating. I even go so far as to recommend moving your office out to the shop floor.

You can always use a conference room for phone calls and private meetings.

When you see an operation day in and day out, you get familiar with it, and any hiccup you witness begs for attention. You lack the insight that you get from seeing an operation firsthand in gemba. Leaders should be careful not to give the impression that their increased presence on the shop floor is to monitor people more. The way to do this is to make sure that processes improve as a direct result of having leaders visiting gemba more often.

Be careful when introducing Japanese terms to team members. If Lean concepts are not being well received, foreign words can sometimes make matters worse. It highlights the fact that something new and different is coming down the pike. Consider sticking with the term shop floor until Lean gets a foothold. The terms are not exactly the same, but they are close enough to use while creating trust in this new way of thinking.

Management by walking around and gemba walks are not the same thing. Gemba walks should have more structure to them. After all, in the past you were expected to just deal with problems. In an improvement focused organization, though, there are constantly people in your workspace watching and asking questions. Have patience. While it can be unnerving to be so closely watched, remember that a good manager is really focusing on the process, not on you. Again, gembapodcast.

Where are you calling in from today? Keivan Zokaei: Thank you, Ron.

Good morning or good afternoon to you. Ron: I love London. You rarely get to do that. Keivan: Thank you, Ron. It was interesting because even then I had two choices. I was in two minds between strategy or Lean and green. They were quite different fields, and I had two very good professors to pick. Ron: What do you do?

Gemba Walk: Where the Real Work Happens

Are you a consultant now? I was tenured academic for a number of years, for about six or seven years. Also, the people who work there left it.

A number of years through my academic career, I decided to become a consultant and try my hand in being a change agent. The quotation can be related to Lean or leadership or really anything. What quotation inspires you?

Gemba (+4-Min MP3, +6-Page PDF)

Keivan: Ron, Dr. Ron: Love Dr. All right, Keivan. The first question I have is a general question.

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Is Lean in itself green? Keivan: Probably not, to be very honest. It depends how conscious you are about the green aspects of it.

Companies, such as Toyota, who are extremely conscious about the environmental performance are also very sustainable. We were fortunate to have access to some Toyota executives and Toyota data not so long ago. We carried out the benchmark of Toyota against other car manufacturers. The results were remarkable because the environmental performance leak almost matched the economic performance leak.

The best performance economically and quality-wise was also the best performance from an environmental point of view, which was quite remarkable. This just shows us that you will be also green if you have environmental consciousness.

Why do you think that is? Keivan: The reason for that is that you will only become green if you are extremely conscious and aware of your green performance. Otherwise, your performance, your environmental performance, is not likely to be that great.

Is that fair? Keivan: That is fair, yes. Ron: What does it take to make a Lean and green business? Keivan: I would say pretty much Lean itself. In order to create a Lean and green business, companies need to adopt a holistic approach — a systematic and holistic approach — towards Lean and green.

The same way that adopting Lean tools does not guarantee creating a Lean company, adopting Lean and green tools will equally not guarantee creating a Lean and green company. What is required is to have the tools, the processes, the leadership, the strategy, and the supply chain. In fact, I call that the Lean and green business system model.

Ron: Give me some examples. Back when I worked in industry, I remember seeing some events that were done where the maintenance department went around and they figured out that there was all these air fittings and so forth that were leaking. Give me some more examples of what a Lean and green company is doing, some very practical, put-your-hands-on-it examples. They are not very big in the US, but they are well-recognized in the US.

They are predominantly a British retailer of clothing and groceries.

They have launched a scorecard. This is probably the main information that we can share with your audience.

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The scorecard is quite remarkable. It covers three areas — environmental, ethical, and Lean. Those are the three pillars of sustainability, by the way — environmental, social, and economic. Not only they are improving economically every day but they are also improving environmentally and socially or ethically every day. Ron: What are they doing?

Keivan: Sure.

Ron: Give me a practical example of what that company did. What are some practical examples of some green improvements that that particular company has made? They will reduce some of the waste. If you reduce your food waste of course it is some Lean improvement. Of course it is some economic improvement. Coincidentally, food waste is also one of the biggest contributors toward global warming. That, coincidentally, is a huge environmental footprint that has been eliminated.

In another example, recently we worked with, in fact, the largest sandwich factory on Earth. We managed to reduce 1, tons of food waste, most of which was bread. In that case, bread was a baked item. Because it was baked, it consumes a lot of energy and it emits a lot of CO2. By eliminating all of that food waste, you have eliminated a huge amount of CO2 as well as saving a lot of money. Ron: My wife would love that.

Ron: What about within an office environment? Are companies like Toyota, do they have practices like that in place? Keivan: Absolutely. Toyota do ties into the environmental footprint.

They do it not only on the shop floor in the manufacturing, but they also do it in the offices.Announcer: Thanks for listening to the Gemba Academy Podcast. Try to focus on finding the weak spots of the process, not of the people. What are some practical examples of some green improvements that that particular company has made?

Thanks again, Keivan. The gemba walk, is an activity that takes management to the front lines to look for waste and opportunities to practice gemba kaizen , or practical shopfloor improvement. The checklist has to include questions that will help you understand the process you are going to observe in a better way.

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