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Kamishibai Intro
Kamishibai Intro
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
• Pareto analysis
• Issue/Countermeasure sheet
RESULT – KAMISHIBAI BOARD
Layout
Process Flow
Audit
Schedule
Pareto by
Card
Pareto by
Area
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.
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
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
CELL ASSOCIATE
CELL ASSOCIATE
CELL ASSOCIATE
CELL ASSOCIATE
CELL ASSOCIATE
DIRECTOR OF OP.
MFG. MANAGER
QUALITY MANG.
EHS
OPTIONAL AUDIT
OPTIONAL AUDIT
OPTIONAL AUDIT
Audit Plan
Month : April 18
Role Auditor Name Daily Weekly Bi-Weekly Monthly Quarterly
1.DINESHKUMAR
Quality Inspector 2.EASWARA MOORTHY
3.IWIN
“Pass” Audit:
Audit Process
“Fail” Audit:
Audit Process