Kobayashi 20 Keys Template

Key No Key Description Stage Score Stage1 Stage 2 Stage3 Stage4 Stage5
1 Cleaning & Organising Untidy. Paper, Dispose of Clean up Organise and Eliminate
Tools, Parts unneeded equipment, mark all causes of dirt
scattered items. Keep clear out sections. and disorder
floor clean corners Organise
storage
2 Rationalising (Hoshin) No clear Clear Instructions Levels work co- Work together
management Responsibility from top broken operatively to co- to create
system down at each ordinate efforts common goals,
level individual skills
3 Improvement Team Activities No desire to get Suggestion Autonomous Alignment of After work team
involved in Scheme. Team Teams begin. teams & activities.
teams activities start Groups: 2 company. Groups: 6
projects pa Groups: 4 projects pa
Individual: 1 projects pa Individual: 5
suggestion / Individual: 2 suggestions /
month suggestions / month
month
4 Reducing Inventory & Lead Times WIP is a Inventory Start a Integrating Make only what
necessary evil reduction handbook- production lines customers want
launched. based inventory results in lower
Inventory reduction inventory. 75%
reduced in at program inventory
least one area reduction
5 Changeover Nothing done Some 10% of SMED on all Single operators
employees learn changeovers machines. can do SMED
SMED are SMED Single files in on all machines
office
6 Value Analysis & Methods Improvement Shotgun Systematic People have Pokayoke and Improvement
approach to improvement learned how to low cost making is
improvement has begun do system automation systematic and
improve at all result in continual
processes doubling
productivity

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 Kobayashi 20 Keys Template
7 Zero Monitoring Manufacturing Low recognition Everyone 10% process All machines All machines
that monitoring recognises that have unmanned can operate are running on
(watching monitoring is operation during during breaks; one-cycle
machines) is waste breaks operators automation zero
waste handle > 1 monitoring
machine
8 Coupled/Synchronised Manufacturing Each workplace Emphasis on Factory Clearly visible
All inter-
functions connections employees set kanban department
independently between up kanban established
walls are
processes stores throughout.
demolished.
Fishbowl offices
Goods and info
flow freely
9 Maintenance Run machines Everyone Operator Full commitment A focused
into the ground understands the responsible for to focused improvement
need for TPM. elimination of 3 improvement. programme is in
OEE is evils Zero breakdown place OEE is
measured. (contamination, goal. Downtime 95%
inadequate reduced by 75%
lubrication,
disoperation)

10 Time Control & Commitment Work & break Morning Supervisors Workers are Rhythm is
times left to meetings are meet to conscientious established.
operators held. Safety establish time about time. No Value adding
discretion equipment is control issues. early stops. work performed
worn at all times Work starts Next day for full shift
promptly. Tools assignments
returned known
11 Quality Quality left to Operators Defect info Pokayoke's are Full pokayoke.
inspectors inspect their passed along being built Zero customer
own products immediately. complaints
Prevention
takes place
immediately

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 Kobayashi 20 Keys Template
12 Supplier Development Manufacturer / Technical Send technical Suppliers and Suppliers have
Supplier assistance is assistance to manufacturers reached a score
relationship given in suppliers. work together of at least 70 on
limited to response to Provide QC and on implementing the 20 keys
purchasing, supplier queries. IE support all 20 keys
acceptance, Support for
price negotiation upstream
process

13 Waste Elimination Little Everyone knows Waste Actual work Actual work
understanding what waste elimination ratio is 85% ratio is at least
of waste really is begins by (Value Add v 95%
operators Waste)
14 Worker Empowerment Improvement is Improvement Workers Low cost Factory makes
someone else's corners set up. participate in automation and uses its
job Teams make making their devices are own automation
their own own tools. designed and devices such as
shelves, tables, SMED has made in house detectors,
etc begun sensors, sorters

15 Skill Versatility No one is Cross training Complete cross Everyone The factory is
intersested in begins. training being embraced the fully able to
skill versatility Willingness to implemented. goal of the adapt to change
learn Everyone's core adaptable by re-assigning
skills have factory. Cross trained
doubled training across employees.
classifications Most on 'Master'
level

© Futurestate Solutions Ltd 2011 www.futurestatesolutions.co.uk Tel: 01204 410062

 Kobayashi 20 Keys Template
16 Scheduling Deliveries rarely Some late Work operations 100% on time Level
on schedule delivery. Non levelled delivery, level schedules, with
uniform throughout the schedules, plus pull, plus level 4
production still month. Clear level 3 on all on all other keys
exists visible keys
schedules

17 Efficiency Control Indirect Labour content Standard and Efficiency Everyone

efficiency reported by actual times set control motivated to
control reporting family. and reviewed. monitored and achieve suitably
used Efficiency charts Graph's kept graphed daily challenging
established goals

18 Shop Floor Information Systems Low awareness Used in limited A factory wide CIM system fine- CIM and POP
of CIM, OA, areas automation tuned after level systems fully
POP information policy 3 in other keys. implemented
developed POP system
implement

19 Energy & Materials Conservation Company wide savings on Comprehensive Full pursuit of
not considered conservation existing programme in conservation
policy begun equipment place
begun
20 Leading Technology & Benchmarking No monitoring Position with Keeping pace One step ahead Site technology
of competitors respect to with average for of industry amongst the
competitors the industry average. Easy best in the
established incorporation of industry.
new Monitors leading
technologies edge technology

© Futurestate Solutions Ltd 2011 www.futurestatesolutions.co.uk Tel: 01204 410062