Kamishibai Boards in Lean Manufacturing. How Do They Work?

We strive to make operations better and optimized, surrounded by constant change. So, how do we keep up and also ensure effective and successful ops?

This is where Kamishibai boards revolutionize the game. These boards got their start long ago in Japanese storytelling. Now they have changed to help factories.

Kamishibai boards combine keeping it simple with making things work well. They use visuals to control processes, assign jobs, and check how things are going.

From improving how efficiently things get done to encouraging constant improvements, these boards have shown they can simplify workflows and increase how much gets made.

Key Highlights:

• Kamishibai boards come from Japanese storytelling traditions long ago. Now they are useful visual tools for factories.
• They are very important for lean manufacturing styles like what Toyota does.
• These boards use a T-card system to clearly assign jobs and check how processes are going.
• They support leadership routines, checking the factory floor, and overseeing work there.
• Using Kamishibai boards improves how efficiently things get done and quality control.
• They encourage always making improvements and lean leadership.
• These boards mix well with other lean methods like 5S and standard processes.
• Any factory wanting to enhance processes would do well looking at these simple yet powerful visual tools. Their mix of plain design and usefulness provides clear value.

What are Kamishibai Boards?

Kamishibai boards have become really important parts of how factories work today, especially places that follow lean styles.

This visual tool’s name comes from an old type of storytelling in Japan. Long ago, storytellers there would use picture boards to tell stories to kids.

In manufacturing now, kamishibai boards have kept the idea of showing pictures to explain things, but are used as a management tool instead.

The boards give a clear at-a-glance view of what processes are like, what tasks need to be done, and how things are going. This lets managers and employees easily see what needs attention or could be improved.

In lean factories that follow Toyota methods, kamishibai boards are key parts of the visual systems used. The boards regularly check processes are right, track progress, and make sure work follows standard guidelines.

They usually have a series of cards or panels representing different jobs, factory steps, or areas.

These simple yet useful visual tools provide transparency and awareness that has proven invaluable for enhancing operations in a variety of settings. Their mix of clear communication and functionality brings notable benefits.

Learn practical tactics for implementing Kamishibai boards and integrating them with other lean methodologies.

Kamishibai Boards in Lean Manufacturing

1. Process-level audits: They facilitate quick and efficient checks of various processes, ensuring that standard operating procedures are being followed.
2. Task allocation: The boards help in assigning and tracking responsibilities among team members.
3. Performance monitoring: They provide a visual representation of key performance indicators (KPIs) and metrics.
4. Problem identification: Kamishibai boards aid in quickly spotting deviations from standards or potential issues in the production process.
5. Continuous improvement: By highlighting areas that need attention, these boards support ongoing efforts to enhance operational efficiency and quality.

Importance in the Toyota Production System

Kamishibai boards play a crucial role in the Toyota Production System (TPS), which is widely regarded as the gold standard for lean manufacturing practices.

The TPS relies heavily on visual management tools to maintain efficiency, quality, and continuous improvement throughout the production process.

Within the Toyota Production System, kamishibai boards are utilized for:

1. Leader standard work: They help managers and supervisors structure their daily routines and ensure that they are regularly engaging with shop floor activities.
2. Gemba walks: Kamishibai boards guide leaders during their gemba walks (shop floor observations), ensuring that they cover all critical areas and processes.
3. Quality control: The boards assist in maintaining high-quality standards by prompting regular checks and audits of various production stages.
4. Workflow visualization: They provide a clear, visual representation of the production status, helping to identify bottlenecks or inefficiencies.
5. Kaizen culture: By highlighting areas for improvement, kamishibai boards support Toyota’s commitment to continuous improvement (kaizen) and employee engagement.

The importance of kamishibai boards in the TPS cannot be overstated. They serve as a cornerstone of Toyota’s lean philosophy, promoting transparency, accountability, and a proactive approach to problem-solving.

By integrating these visual control tools into their daily operations, Toyota has been able to maintain its position as a leader in manufacturing efficiency and quality.

Components and Structure of Kamishibai Boards

Kamishibai boards are essential visual control tools in lean manufacturing, designed to streamline processes and enhance operational efficiency.

To fully appreciate their effectiveness, it’s crucial to understand their components and structure. Let’s dive into the key elements that make up these powerful lean tools.

T-card System Explained

At the heart of kamishibai boards lies the T-card system, a simple yet ingenious method for tracking tasks and processes. The “T” in T-card stands for “task” or “time,” depending on the specific application. Here’s how it works:

• Cards are typically rectangular, with a portion protruding at the top, forming a T-shape.
• Each card represents a specific task, process, or audit item.
• The cards are color-coded to indicate status: green for completed or satisfactory, red for incomplete or requiring attention.
• Cards are arranged in a grid or matrix on the board, allowing for easy visualization of multiple tasks or processes simultaneously.

The T-card system enables quick status checks and promotes accountability, as team members can easily see which tasks need attention and who is responsible for them.

Visual Control Elements

Kamishibai boards incorporate various visual control elements to enhance their effectiveness in workflow visualization and performance monitoring. These elements include:

• Color coding: As mentioned earlier, colors play a crucial role in quickly conveying status information. Green typically indicates “good” or “complete,” while red signals “attention required” or “incomplete.”
• Icons and symbols: Simple, universally understood icons can represent different types of tasks, departments, or process stages, making the board easily interpretable at a glance.
• Progress indicators: Visual indicators such as progress bars or percentages can show how far along a task or project is.
• Due dates and deadlines: Displayed timeframes help prioritize tasks and ensure timely completion.
• Responsibility assignments: Names or photos of team members responsible for specific tasks promote accountability and clear communication.

These visual elements work together to create a comprehensive snapshot of the current state of operations, allowing for quick decision-making and problem identification.

Task Allocation and Sequencing within Kamishibai Boards

One of the key strengths of kamishibai boards is their ability to facilitate efficient task allocation and sequencing. This is achieved through:

• Prioritization matrix: Tasks can be arranged on the board based on their urgency and importance, helping teams focus on high-priority items first.
• Time-based sequencing: Cards can be organized chronologically, showing the order in which tasks should be completed or audits performed.
• Role-based allocation: The board can be divided into sections for different team members or departments, clearly showing who is responsible for which tasks.
• Rotation system: To ensure comprehensive coverage of all processes, kamishibai boards often incorporate a rotation system for audits or checks, preventing oversight of any critical areas.

By structuring task allocation and sequencing in this way, kamishibai boards support the principles of lean manufacturing by minimizing waste, improving flow, and ensuring that all necessary processes are consistently monitored and executed.

Want to develop proficiency with the T-card system and other elements that make Kamishibai boards effective?

Implementing Kamishibai Boards in Manufacturing

Implementing kamishibai boards in manufacturing environments is a game-changer for organizations looking to streamline their operations and boost efficiency.

These visual control tools, rooted in the Toyota Production System and lean manufacturing principles, offer a practical approach to enhancing workplace organization and productivity.

Dive into how kamishibai boards can be effectively integrated into various aspects of manufacturing processes.

Integration with Leader Standard Work

Leader standard work is a crucial component of lean manufacturing, and kamishibai boards serve as an excellent complement to this practice. By incorporating kamishibai boards into leader standard work, organizations can:

• Standardize leadership activities: Kamishibai boards provide a structured framework for leaders to follow, ensuring consistency in their daily routines and responsibilities.
• Enhance accountability: The visual nature of kamishibai boards makes it easy to track and monitor leadership tasks, promoting a culture of accountability among managers and supervisors.
• Facilitate continuous improvement: As leaders regularly interact with kamishibai boards, they can identify areas for process improvement and implement kaizen initiatives more effectively.

For example, a production supervisor might use a kamishibai board to schedule and track daily team huddles, equipment checks, and performance reviews. This integration ensures that critical leadership tasks are consistently performed and easily monitored.

Process-level Audits and Gemba Walks with Kamishibai Boards

Kamishibai boards excel in supporting process-level audits and gemba walks, two essential practices in lean manufacturing. Here’s how they contribute:

• Structured audit process: Kamishibai boards provide a systematic approach to conducting audits, ensuring that all critical areas are regularly checked and evaluated.
• Real-time feedback: During Gemba walks, leaders can use kamishibai boards to provide immediate feedback on processes, identifying both strengths and areas for improvement.
• Visual indicators: The T-card system commonly used in kamishibai boards offers clear visual cues about the status of different processes, making it easy to spot issues during audits and walks.

For instance, during a Gemba walk, a manager might use a kamishibai board to randomly select and audit specific workstations or processes. This approach ensures comprehensive coverage of the shop floor over time and helps identify potential issues before they escalate.

Shop Floor Management and Visual Management

Kamishibai boards play a pivotal role in effective shop floor management and visual management strategies. Here’s how they contribute to these areas:

• Enhanced visibility: Kamishibai boards serve as centralized hubs for important information, making it easy for all employees to stay informed about production status, quality metrics, and safety concerns.
• Workflow visualization: By displaying task allocation and sequencing, kamishibai boards help teams understand their roles and responsibilities within the production process.
• Performance monitoring: These boards enable quick and easy tracking of key performance indicators (KPIs), allowing managers to identify trends and take corrective action when necessary.

For example, a manufacturing plant might use a large kamishibai board in a central location to display daily production targets, quality metrics, and safety reminders.

Smaller, department-specific boards could be used to manage task allocation and track progress on specific production lines.

With kamishibai boards manufacturing organizations can significantly enhance their operational efficiency and foster a culture of continuous improvement.

These visual control tools not only support lean manufacturing principles but also contribute to creating a more engaged and productive workforce.

Benefits of Using Kamishibai Boards

Kamishibai boards have become an integral part of lean manufacturing practices, offering numerous advantages to organizations that implement them effectively.

Let’s look at the key benefits of using kamishibai boards.

Enhancing Operational Efficiency

Kamishibai boards are powerful visual control tools that significantly boost operational efficiency in manufacturing environments.

By providing a clear, at-a-glance view of task allocation and process status, these boards streamline workflow and reduce time wasted on unnecessary communication or confusion.

One of the primary ways kamishibai boards enhance efficiency is through improved task execution.

The T-card system, a core component of kamishibai boards, allows managers to easily assign and track tasks, ensuring that every team member knows their responsibilities and deadlines. This clarity in task allocation minimizes downtime and increases productivity.

Moreover, kamishibai boards support lean manufacturing principles by highlighting areas of waste or inefficiency. As part of the Toyota Production System, these boards help identify bottlenecks, overproduction, or underutilized resources.

By making these issues visible, managers can quickly address them, leading to smoother operations and increased overall efficiency.

Improving Quality Control and Problem Identification with Kamishibai Boards

Quality control is a critical aspect of any manufacturing process, and Kamishibai boards excel in this area. By incorporating process-level audits into the kamishibai system, organizations can maintain high standards of quality consistently across their operations.

The visual nature of these boards makes it easier to spot deviations from standard work procedures. When issues arise, they are immediately visible on the board, allowing for quick identification and resolution.

This rapid problem identification is crucial in maintaining product quality and preventing defects from progressing further down the production line.

Furthermore, kamishibai boards facilitate regular Gemba walks, where managers can observe processes firsthand and identify potential quality issues or areas for improvement.

These walks, combined with the visual indicators on the kamishibai board, create a powerful system for maintaining and improving quality control.

Facilitating Continuous Improvement and Kaizen Culture

Perhaps one of the most significant benefits of kamishibai boards is their role in fostering a culture of continuous improvement, also known as kaizen.

By making processes and their outcomes visible to everyone, these boards encourage all employees to engage in problem-solving and suggest improvements.

The regular audits and checks associated with these boards create numerous opportunities for identifying areas of improvement.

As employees become accustomed to this system, they naturally begin to think critically about their work processes and how they can be enhanced. This mindset is at the heart of kaizen culture and is crucial for long-term success in lean manufacturing.

Kamishibai boards also support lean leadership by providing a framework for managers to coach and develop their teams.

Through regular interactions centered around the kamishibai board, leaders can share knowledge, provide feedback, and encourage innovative thinking among their team members.

Interested in leveraging Kamishibai boards to foster a kaizen culture? Learn more about the Systems Thinking program for identifying improvement opportunities at a systemic level.

Best Practices for Kamishibai Board Implementation

Implementing kamishibai boards effectively requires careful planning and adherence to best practices.

Let’s explore how to integrate these visual control tools with other lean methodologies and processes to maximize their impact on operational efficiency and continuous improvement.

Integrating with 5S Methodology

The 5S methodology (Sort, Set in order, Shine, Standardize, and Sustain) is a cornerstone of lean manufacturing, and kamishibai boards can be seamlessly integrated into this framework. Here’s how:

• Sort: Use kamishibai boards to identify and categorize tasks, making it easier to eliminate unnecessary activities.
• Set in order: Organize kamishibai cards in a logical sequence, mirroring the workflow on the shop floor.
• Shine: Include cleaning and maintenance tasks on the kamishibai board to ensure a tidy workspace.
• Standardize: Use the boards to reinforce standard operating procedures across different shifts and departments.
• Sustain: Regular audits using these boards help maintain the 5S culture over time.

By aligning kamishibai boards with 5S principles, companies can create a more organized, efficient, and visually managed workplace.

Aligning with Standard Work Procedures

Standard work is a crucial element of lean manufacturing, and kamishibai boards can play a vital role in reinforcing these procedures:

• Document standard work: Use kamishibai cards to outline key steps in standard work procedures, making them easily accessible to all employees.
• Visual cues: Incorporate visual indicators on the boards that correspond to standard work instructions, making it easier for workers to follow established processes.
• Regular updates: As standard work procedures evolve, update these boards to reflect these changes, ensuring that all team members are working from the most current information.
• Training tool: Use them as a training aid for new employees, helping them quickly understand and adopt standard work practices.

By aligning kamishibai boards with standard work procedures, organizations can improve consistency, reduce errors, and enhance overall operational efficiency.

Balancing Task Execution and Performance Monitoring with Kamishibai Boards

One of the key challenges in implementing kamishibai boards is striking the right balance between task execution and performance monitoring. Here are some strategies to achieve this balance:

• Prioritize tasks: Use color-coding or other visual cues on the kamishibai board to highlight high-priority tasks that require immediate attention.
• Set realistic targets: Ensure that the number and complexity of tasks on the board are achievable within the given timeframe to avoid overwhelming employees.
• Incorporate performance metrics: Include key performance indicators (KPIs) on the board to provide context for task execution and help team members understand how their work contributes to overall goals.
• Regular review cycles: Establish a routine for reviewing and updating the kamishibai board, allowing for adjustments based on changing priorities and performance data.
• Encourage employee feedback: Create a mechanism for workers to provide input on the kamishibai system, fostering a sense of ownership and continuous improvement.

By carefully balancing task execution and performance monitoring, organizations can use these boards to drive productivity while maintaining employee engagement and satisfaction.

Implementing these best practices will help ensure that these boards become an integral part of your lean manufacturing strategy, contributing to improved operational efficiency, quality control, and continuous improvement efforts.

As with any lean tool, the key to success lies in consistent application, regular evaluation, and a commitment to ongoing refinement of the process.

Kamishibai Boards and Lean Leadership

Kamishibai boards play a crucial role in developing and supporting lean leadership within organizations. These visual control tools not only facilitate efficient operations but also empower leaders to drive continuous improvement and foster a culture of accountability.

Let’s explore how kamishibai boards contribute to lean leadership development and organizational success.

Developing Lean Leaders Through Visual Management

Kamishibai boards serve as powerful visual management tools that help develop lean leaders in several ways:

1. Enhanced visibility: Leaders can quickly assess the status of various processes and identify areas requiring attention, allowing for more informed decision-making.
2. Standardized leadership practices: By incorporating leader standard work into these boards, organizations ensure consistent leadership behaviors and routines across all levels.
3. Gemba walk facilitation: These boards provide a structured approach to Gemba walks, enabling leaders to engage with frontline employees and gain firsthand insights into operations.
4. Data-driven leadership: The visual representation of performance metrics on these boards encourages leaders to make decisions based on real-time data rather than assumptions.
5. Continuous learning: As leaders interact with these boards regularly, they develop a deeper understanding of processes and become more adept at identifying improvement opportunities.

Enhancing Workplace Organization and Productivity with Kamishibai Boards

Kamishibai boards contribute significantly to workplace organization and productivity improvement:

1. 5S methodology integration: These boards can be used to reinforce 5S principles (Sort, Set in order, Shine, Standardize, Sustain), ensuring a well-organized and efficient workplace.
2. Visual indicators: The use of color-coded cards and visual cues on these boards helps quickly communicate the status of tasks and processes, reducing time wasted on information gathering.
3. Workflow visualization: By displaying the sequence of tasks and their current status, these boards help optimize workflow and reduce bottlenecks.
4. Resource allocation: Leaders can use these boards to allocate resources more effectively based on real-time production status and task priorities.
5. Standardized work procedures: These board reinforce adherence to standard work, ensuring consistency and efficiency across operations.

Fostering a Culture of Accountability and Improvement

Kamishibai boards are instrumental in creating a culture of accountability and continuous improvement:

1. Transparent performance tracking: By making performance metrics visible to all, these boards promote accountability at all levels of the organization.
2. Regular audits and checks: The T-card system inherent in these boards ensures that routine checks and audits are conducted consistently, reinforcing a sense of responsibility among team members.
3. Problem identification and resolution: They facilitate quick identification of issues, enabling prompt resolution and preventing small problems from escalating.
4. Employee engagement: By involving employees in the kamishibai process, organizations encourage active participation in improvement initiatives and problem-solving.
5. Kaizen culture: The visual nature of these boards supports the continuous improvement mindset, making it easier for teams to identify and implement incremental changes.
6. Lean implementation support: They serve as a tangible representation of lean principles, helping to reinforce lean concepts and practices throughout the organization.
7. Cross-functional collaboration: The visibility provided by these boards encourages collaboration between different departments, fostering a unified approach to improvement.

Future of Kamishibai Boards in Modern Manufacturing

As we look towards the future of lean manufacturing and continuous improvement, kamishibai boards are evolving to meet the demands of modern industry.

This traditional visual management tool is adapting to new technologies and expanding its applications beyond the shop floor.

Digital Adaptations of Kamishibai Systems

The digital transformation of kamishibai boards is revolutionizing how companies approach visual control and process improvement.

Digital kamishibai systems retain the core principles of the traditional boards while leveraging technology to enhance their functionality and reach.

Key features of digital kamishibai systems include:

• Real-time updates: Digital boards can be updated instantly, allowing for more dynamic task allocation and performance monitoring.
• Remote access: Team members can view and interact with these boards from anywhere, facilitating better communication across distributed teams.
• Data analytics: Digital systems can automatically collect and analyze data from kamishibai audits, providing deeper insights into operational efficiency and areas for improvement.
• Integration with other digital tools: These boards can be linked with other software systems, such as enterprise resource planning (ERP) or manufacturing execution systems (MES), for a more comprehensive view of operations.

These digital adaptations are making kamishibai boards more flexible and powerful tools for lean implementation and continuous improvement.

Integration of Kamishibai Boards with Industry 4.0 Technologies

As Industry 4.0 technologies continue transforming manufacturing, kamishibai boards are finding new ways to integrate with these advanced systems.

This integration creates more intelligent and responsive visual management tools that can drive operational efficiency to new heights.

Some examples of how kamishibai boards are integrating with Industry 4.0 technologies include:

• Internet of Things (IoT) connectivity: These boards can be linked to IoT sensors on equipment and products, automatically triggering audits or task assignments based on real-time data.
• Artificial Intelligence (AI) and Machine Learning (ML): These technologies can analyze patterns in Kamishibai audit data to predict potential issues and suggest proactive improvements.
• Augmented Reality (AR): AR can enhance gemba walks by overlaying kamishibai board information onto the physical environment, providing leaders contextual data as they move through the workplace.
• Blockchain: This technology can be used to create tamper-proof records of kamishibai audits and improvements, ensuring transparency and accountability in the continuous improvement process.

By embracing these technologies, kamishibai boards are becoming even more effective tools for lean manufacturing and shop floor management in the digital age.

Expanding Applications Beyond Manufacturing

While kamishibai boards have their roots in manufacturing, their principles of visual control, task allocation, and continuous improvement are valuable in many other industries and organizational functions.

As a result, we’re seeing them being adapted for use in various non-manufacturing contexts.

Some areas where kamishibai boards are finding new applications include:

• Healthcare: Hospitals and clinics are using these boards to manage patient care processes, ensure compliance with safety protocols, and drive continuous improvement in healthcare delivery.
• Software development: Agile development teams are adapting Kamishibai principles to visualize workflow, manage code reviews, and ensure adherence to coding standards.
• Education: Schools and universities are using Kamishibai-inspired systems to track student progress, manage classroom activities, and drive continuous improvement in teaching methods.
• Service industries: From hospitality to financial services, companies are using these boards to standardize processes, improve customer service, and drive operational efficiency.
• Project management: Kamishibai principles are being applied to project management boards, helping teams visualize task progress, allocate resources, and identify potential bottlenecks.

These expanded applications demonstrate the versatility and enduring value of kamishibai boards as tools for visual management and continuous improvement across various sectors.

Original Article: https://www.6sigma.us/six-sigma-in-focus/kamishibai-boards/