Kamishibai Vs Layered Process Audit

Kamishibai vs Layered Process Audit: A
Comparative Study
Abstract
This paper aims to compare Kamishibai and Layered Process Audits (LPA), two prominent
methodologies used in the manufacturing industry to ensure quality and process adherence.
Kamishibai, originating from Japan, is a visual management tool that emphasizes random audits
and employee involvement, while LPA, prevalent in Western industries, focuses on systematic
and hierarchical audits. Both methodologies aim to enhance process reliability, but their
approaches and implementations differ significantly.
Introduction
In manufacturing, maintaining consistent quality and adhering to standard processes are critical
for operational efficiency and customer satisfaction. Kamishibai and Layered Process Audits are
two methodologies employed to achieve these goals. This paper explores the origins,
methodologies, benefits, and challenges of each approach to provide a comprehensive
understanding of their applications in various industrial contexts.
Kamishibai
Origins and Methodology
Kamishibai, which means "paper drama" in Japanese, has its roots in a traditional storytelling
method used in Japan. In the manufacturing context, Kamishibai is a visual management tool
used to perform random audits of the shop floor processes. It involves a board with cards that list
various tasks or audit points, which are selected at random by employees to ensure compliance
and identify potential issues.
Implementation
1. Visual Management: The Kamishibai board is prominently displayed on the shop floor,
with cards representing different audit tasks.
2. Random Audits: Employees select cards randomly to perform audits, ensuring that all
aspects of the process are regularly reviewed.
3. Employee Involvement: The system encourages participation from all levels of the
workforce, promoting a culture of continuous improvement and accountability.
Benefits
 Engagement: Involves all employees, fostering a sense of ownership and responsibility.

 Flexibility: Random audits prevent predictability and complacency.
 Visual Cues: Easy to understand and implement, enhancing transparency and
communication.
Challenges
 Consistency: Random nature may lead to inconsistencies in audit coverage.

 Training: Requires thorough training to ensure all employees can effectively perform
audits.
 Scalability: May be challenging to implement in larger, more complex operations.
Layered Process Audit (LPA)

Origins and Methodology
Layered Process Audit is a structured approach used to verify adherence to standard processes at
multiple levels of an organization. LPAs involve different layers of management conducting
regular, systematic audits to ensure compliance and identify areas for improvement. This
methodology is widely used in the automotive industry and other sectors where process
reliability is paramount.
Implementation
1. Structured Audits: Audits are conducted at regular intervals by different layers of

management, from frontline supervisors to senior executives.
2. Standardized Checklists: Auditors use standardized checklists to ensure consistency
and thoroughness.
3. Feedback Loop: Findings are documented, and corrective actions are implemented and
tracked.
Benefits
 Consistency: Regular, structured audits ensure comprehensive coverage and reliability.

 Accountability: Involvement of multiple management layers enhances accountability
and oversight.
 Continuous Improvement: Systematic approach facilitates ongoing process
improvements.
Challenges
 Resource Intensive: Requires significant time and resources to conduct audits and
follow up on findings.
 Rigidity: Structured nature may lead to rigidity and resistance to change.
 Training and Buy-in: Ensuring all layers of management are committed and trained can
be challenging.
Comparative Analysis
Similarities
 Objective: Both methodologies aim to ensure process adherence and quality

improvement.
 Involvement: Require participation from various levels of the organization.
 Documentation: Emphasize documenting findings and implementing corrective actions.
Differences
 Approach: Kamishibai relies on random audits by employees, while LPA uses structured
audits by multiple management layers.
 Flexibility vs. Structure: Kamishibai offers flexibility and adaptability, whereas LPA
provides consistency and thoroughness.
 Cultural Fit: Kamishibai aligns with a more inclusive, participatory culture, while LPA
fits hierarchical, process-driven environments.
Case Studies
Kamishibai in Toyota
Toyota has successfully implemented Kamishibai as part of its Lean Manufacturing principles.
The random audit system has helped Toyota maintain high standards of quality and efficiency by
involving all employees in the continuous improvement process .
LPA in General Motors
General Motors (GM) has employed Layered Process Audits to enhance process reliability and
quality in its manufacturing plants. The structured audit approach has enabled GM to maintain
consistent standards and identify potential issues proactively .
Conclusion
Both Kamishibai and Layered Process Audits offer valuable approaches to ensuring process
adherence and quality in manufacturing. The choice between the two depends on the
organizational culture, operational complexity, and specific needs of the business. While
Kamishibai fosters employee engagement and flexibility, LPA provides a structured and
systematic framework for continuous improvement.
References
1. Liker, J. K. (2004). The Toyota Way: 14 Management Principles from the World's
Greatest Manufacturer. McGraw-Hill.
2. Ohno, T. (1988). Toyota Production System: Beyond Large-Scale Production.
Productivity Press.
3. Shingo, S. (1989). A Study of the Toyota Production System from an Industrial
Engineering Viewpoint. Productivity Press.
4. Sorensen, C. (2010). The Implementation of Layered Process Audits at General Motors.
Quality Progress.

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Kamishibai vs Layered Process Audit: A

 Engagement: Involves all employees, fostering a sense of ownership and responsibility.

 Consistency: Random nature may lead to inconsistencies in audit coverage.

Layered Process Audit (LPA)

1. Structured Audits: Audits are conducted at regular intervals by different layers of

 Consistency: Regular, structured audits ensure comprehensive coverage and reliability.

 Objective: Both methodologies aim to ensure process adherence and quality

LPA in General Motors

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