1
1 986 ( K a i z e n ) 1993 New Shorter Oxford [1] ( ) [1] K a i z e n Gemba Kaizen 2
(ZD) (JIT) 1.1 3
PDCA /SDCA 1.1.1 ( M a i n t e n a n c e ) ( I m p r o v e m e n t ) 1-1 1-1 4
1-2 1-2 ( K a i z e n ) ( I n n o v a t i o n ) ( ) 1.1.2 5
( P D C A ) ( S D C A ) ( Q C D ) ( T Q M (JIT) (TPM) 1.1.3 PDCA /SDCA ( P l a n ) ( D o ) ( C h e c k ) ( A c t i o n ) P D C A P D C A P D C A ( 1-3) ( ) P D C A P D C A 6
PDCA P D C A ( S t a n d a r d i z e ) (Do) (Check) (Action)SDCA ( 1-4) A P A S C D C D 1-3 PDCA PDCA S D C A P D C A S D C P D C A 1-4 SDCA 1.1.4 7
1.1.5 1.1.6 A ( ) B ( ) C ( ) ( ) ( ) 8
1.2 / ( ) 1.2.1 / ( T Q C / T Q M ) ( Total Quality Control) (Total Quality Management) T Q C / T Q M T Q C / T Q M 9
T Q C / T Q M T Q C / T Q M Q T T Q C / T Q M T TQC/TQM C TQC/TQM T Q C / T Q M T Q C / T Q M 1.2.2 (JIT) (Just In Ti m e ) J I T ( Takt Ti m e ) (Cycle Ti m e ) ( O n e - P i e c e 10
F l o w )(Pull Production) ( A u t o n o m a t i o n ) U J I T 1.2.3 (TPM) ( Total Productive M a i n t e n a n c e ) T Q M T P M T P M T Q M T P 5 S T P M 5 S T P M 1.2.4 11
10 1.2.5 ( ) 1.2.6 12
1.2.7 ( Q C D ) ( Q C S ) QCD QCS 13
Q C D Q C D Q C D QCD 14
2 5S Muda
1995 1 (Joop Bokern) 5 10 16
2.1 ( ) 2-1 17
2-1 (Eric Machiels) 18
2-2 3 K ( K i k e n ) ( K i t a n a i ) ( K i t s u i ) 3 K 2-2 19
( ) ( ) 2-2 2-2 2-1 ( 1995 ) 20
( ) 21
QCD ( ) 2.2 ( Q C D ) 2-3 Q C D 22
( 3 ) 5S Muda 2-3 2.3 Q C D 23
3 5 S M u d a ( ) Q C D 3 Q C D M u d a 5 S ( 4 ) 2.4 5S 5 S 5 5 S 5 5 S 5 S M u d a 5 S 24
5 ( 5S 5 ) 1 ( B e w i l d e r e d ) 2.5 Muda M u d a M u d a 25
400 ( D a l l a s - F o r t Wo r t h ) ( M u d a ) 26
100 1 100 100 ( 6 Muda) M u d a M u d a 5S 5S 27
( 7 ) 2.6 5 1. ( ) 2. ( ) 3. 4. 5. 2.6.1 28
(Kristianto Jahja)? 29
30
( ) 31
30 30 32
24. 5 43 33
2.6.2 34
( ) 2.6.3 35
2.6.4 36
9 0 5 5 5 5 ( ) 37
2.6.5 Q C D Q C D 38
( Te m p l e ) ( G i o rg i ) (Fred Giorg e ) Muda 39
( Tony Puglio) 5 90 40
2.7 ( ) ( ) 5 ( ) ( ) ( ) 41
( ) ( ) 42
3
3.1 3-1 3-1 ( 1 ) ( ) ( 2 ) ( ) 4 ( D R ) 3-1 44
3-1 45
8 12 ( Q C ) 1 7 ( 1 8 ) 46
( Q F D ) 3-1 Q F D ( Q A ) 3.2 Q F D 47
( 2 ) ( S Q C ) S Q C S Q C SQC ( ) ( Y H P ) 1978 1982 4 000ppm( ) 3 p p m Y H P 1978 1 979 1980 1 982 Y H P 48
Y H P 4 000ppm 40 p p m ( 3-2 ) 40 p p m Y H P ( 3-3 ) ( P C ) Y H P Y H P 1 982 3 p p m 3-2 1 49
3-3 2 (5S) Muda 50
1 /10 S Q C 3.3 51
1. 2. 3. M u d a 7 6 1. 2. 3. 4. 5. 6. 7. Muda 3.3.1 52
( ) 5M 3.3.2 ( ) 3.3.3 53
3.3.4 15 ( ) ( ) 54
3.3.5 3.3.6 4 2 10 3.3.7 55
M u d a 3.3.8 3 3.4 56
( J I T ) JIT ( 11 ) 3.5 57
Q C D 3 58
4 /ISO 9000/QS 9000
4.1 (SDCA) (PDCA) 2 60
( ) 10 % 61
4-1 SDCA PDCA 4-1 ( S D C A ) ( P D C A ) 4.2 Q C D 62
QCD 4.3 4.3.1 63
4.3.2 4.3.3 4.3.4 64
4.3.5 65
4.3.6 4.3.7 4.3.8 4.3.9 66
A B A B 4.4 80 T Q M 1985 67
P D C A ( 3-1 ) Q A 4.5 ( P D C A ) 1 4 P ( ) 5 D ( ) 6 C ( ) 7 8 A ( ) 68
(1) (2) (3) (4) (5) (6) (7) (8) 4.6 /ISO 9000/QS 9000 ( ISO 9000 QS 9000) 69
Muda ( 5S) M u d a ISO 9000 Q S 9000 M u d a 1 9 6 1 4 20 3 2 000 98 6 70
99.2 60 ( 2 3 ) 71
5 5 S 5 5 5S5 5S
5 ( 5 S ) ( 3 ) 2-3 5 S ( ) M u d a 5S Muda M u d a 5.1 5 5 1. (Seiri) 74
5S 5 2. (Seiton) 3. (Seiso) 4. (Seiketsu) 3 5. (Shitsuke) 5S 5S 5C 5.1.1 5S 1. Sort( ) 2. Straighten( ) 3. Scrub( ) 4. Systematize( ) 5. Standardize( ) 4 5.1.2 5C 1. Clear out( ) 2. Configure( ) 75
3. Clean & Check( ) 4. Conform( ) 5. Custom & Practice( ) 5.2 5S5 5.2.1 30 5S 76
5S 5 30 ( ) 20 77
78
5S 5 5.2.2 5 S ( ) 5 5 79
A 1 B 2 ( ) 5.2.3 80
5S 5 ( ) ( ) ) 5.2.4 81
5 S 5.2.5 5 S 5 ( ) ( ) ( ) 3 ( ) 5S 5 S 82
5S 5 5 S 5 S 5 1. 2. 3. 4. 5. 5 S 5 S 5S 5.3 5S 83
5 S 5 S 5 S 5 Muda 5 S 5S M u d a Muda Muda 5S 84
5S 5 5 85
6 M u d a Muda Muda Muda Muda Muda Muda Muda Muda Muda
M u d a M u d M u d a M u d ( ) M u d a 7 1. Muda 2. Muda 3. Muda 4. Muda 5. Muda 6. Muda 7. Muda 6.1 Muda M u d a 88
Muda M u d a M u d a M u d ( ) 6.2 Muda 89
M u d a 6.3 Muda 90
Muda M u d a M u d a M u d a M u d a 6.4 Muda M u d a M u d a 91
M u d a 6.5 Muda M u d a M u d a M u d a M u d a Muda 6.6 Muda M u d a 92
Muda M u d a M u d a M u d a M u d a 6.7 Muda M u d a M u d a (Greg Back) 93
( 10 ) ( ) 5. 5 5 S 3.5 M u d a M u d a M u d a M u d a 6-1 ( S e rge LeBerre) 94
Muda M u d a M u d a 6-1 Muda Muda Muda Muda McGraw-Hill 1986 ) 95
(Less Engineering) ( 6-2) 6-2 ( ) 3 1. 2. 3. 9 3 % 96
Muda Muda 6.8 Muda M u d a M u d a 7 M u d a M u d a M u d a 7 M u d M u d a M u d a M u d a Muda 6.9 Muda M u d a 97
M u d a M u d a 6.9.1 M u d a 6.9.2 Muda 98
Muda M u d a Muda M u d a Muda 99
7
2 (QCD 5 S ( M a r i n a Calcagni) 102
7.1 (University of New South Wa l e s ) (Bill Ford) (Dick Dusseldorp) 103
5 5 S 5 M u d a ( ) 5 S 1. 2. 3. 4. 50 5. 6. 7. 104
8. 5 9. 10. 10 (Jim Crawford) ( E x c e l ) 105
L e y l a n d 7.2 106
J K ( ) ZD( ) 107
7.3 Q C D 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 108
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 5 S M u d a 5 5 S 5 M u d a 8 109
8 5M 5S
( Q C D ) 8.1 112
( ) 8.2 QCD 8.3 5M 5 M ( M a n p o w e r ) ( M a c h i n e s ) ( M a t e r i a l s ) ( M e t h o d s ) 113
( M e a s u r e m e n t s ) 5 M 5 8.3.1 8.3.2 114
8.3.3 8.3.4 8.3.5 115
8.4 5S 5 S 5 S 5S ( ) ( ) ( ) ( 116
) ( S ) ( ) 5S 5 S 8.5 ( ) 117
Q C D ( ) ( 10 ) (Overall Equipment Efficiency, OEE) 118
8.6 6 ( 1 6 ) ( 6 1. 5 ) ( ) ( 119
64 65 ) 10 400 4 000 20 80 000 1 500 000 1 000 1 120
( ) ( ) 121
9
50 (Management Training Program, MTP) ( Training Within Industries, T W I ) M T P TWI (Alan G. Robinson) (Dean M. Schroaeder) TWI ( 3 5 1993 ) ( W. Edward Deming) (Joseph Juran) T W I 1 000 T W I 1992 T W I 124
TWI T W I 1950 T W I T W I 1992 TWI 1 935 1 937 10 T W I T W I T W I 1992 T W I 3 (Job Instruction, JI) (Job Method, JM) (Job Relations) 125
M T P ( M I T I ) ( ) 50 M T P (Sam Stern) 6 2 1995 ) 1 994 300 MTP MTP 3 1. 2. 3. 126
P D C A ( P D C A ) M T P T W I 5 W 1 H W H Y ( ) W H AT ( ) W H E R E ( ) W H E N ( ) W H O ( ) H O W ( ) 5 W 1 H 50 M T P T W I ( Q C D ) 5 S ( ) ( To t a l Quality Control, TQC) ( Total Productive Maintenance, TPM) (Just In Time, JIT) T W I 9.1 20 127
( ) 3 M ( M a n p o w e r ) ( M a t e r i a l s ) ( M a c h i n e ) ( M e t h o d s ) ( M e a s u r e m e n t ) 5 M Q C D ( M o r a l e ) (Safety) QCDMS Q C D 3 M M u d a 128
3 3 9-1 ( ) ( Q C D ) ( ) ( 5 M ) 129
130
Q C D ( ) 1 9 7 0 M T P M T P M T P 10 T W I J I J M J R M I P 1976 131
T W I Yoshida English School Y E S ( ) ( ) 132
3 9.2 ( ) ( A s a i c h i ) 133
5S 3 ( A B C ) 134
( 9-1) 9-1 A B C 70~80 15~20 10~15 ( ) ( ) ( ) ( ) A B C 3 9-2 135
1. 1995 10 9 2 2. 123456-G1062 3. (F-3214) 4. 4 920 0.43 5. ( ) 6. ( / / ) 4 7. 8. 9-2 ( ) (SOP) ( ) 136
( ) 9.3 (Acceptable Quality Level, AQL), AQL 1 137
1 9 8 0 0. 1 30 p p m 5 0 p p m ( ) QA 9-3 Q A Q A 138
C B A / /3 /6 12 500 50 10 ppm( ) 0.5 0.1 0.01 0.1 0.05 0 (a) 55 34 / 16 5S 31 6 7 (b) #1 #2 #3 #4 #5 #6 (c) 9-3 139
9.4 Q C D Q C D 9.5 140
5 M 1. 2. Q C D 3 141
QCD 2 3 142
10 TAM TAM TAM TAM TA M
( Toyota Astra Motor Company) ( P. T. Astra International) 1971 5 000 1 9 9 1 5 S ( TA M ) (TMC) 1992 TA M 144
(Eddie Paino) T M C TMC TAM 8 1 2 1 2 4 1 2 4 1 TA M 10-1 10-1 TAM ( ) 145
(QCDSM) 20 10.1 TAM ( 1 ) ( ) ( 2 ) ( 146
) ( ) (TPM) 5 ( 147
) ( ) 5S TAM 148
5S 10.2 TAM 5 149
10.3 TAM ( M u d a 10 9 ( ) 200 10 9/200 0.45 TA M TA M 10.4 TAM 150
10.5 5S TA M 1. 151
2. 3 10.5.1 TA M A. 1. 2. 3. a. b. 4. 5 B. 152
1. 2. 3. 4. a. b. c. 5. C. 1. a. b. 2. 3. 4. 5. 5S D. 1. 2. 153
10.5.2 TAM TA M ( T P M ) A. 1. a. b. 2. a. b. c. 3. a. b. c. d. e. f. 4. a. 154
b. c. 5. a. b. c. 6. a. b, B. 1. 2. 3. a. b. 4. a. b. 5. a. b. 6. a. 155
b. C. 1. a. b. c. 2. a. b. c. 3. a. b. 4. 10.5.3 TA M 1. a. 156
b. ( ) c. 2. ( ) a. b. 3. a. b. 4. a. b. 5. a. b. 6. a. b. 10.5.4 TA M 157
1. a. b. c. 2. a. b. 3. a. b. 4. a. b. c. 5. a. b. c. d. 6. a. 158
(Personal Touch Activities, PTA ) ( ) 7. a. b. c. d. 8. a. b. c. d. 9. a. b. c. d. 10. a. b. c. 159
10.5.5 TA M TAM TAM 1. a. b. 2. a. b. c. d. e. 3. 10.6 TA M TA M 1. 160
2. TAM 25 M u d a ( ) ( ) ( ) 10.6.1 (On-the-Job Training, OJT) 161
( Toyota Job Instruction, TJI) T W I ( Training Within Industry ) TWI ( J I T ) ( T P S ) 10.6.2 TA M 162
TA M 163
10.7 25 1995 7 500 1990 10 % 80 400 6 TA M (Kristianto Johja) 150 TAM TA M 10 164
11 JIT
( Q C D ) 3 (TQM) (1) ( T Q C ) (2) (TPM) (3) (JIT) J I T (Lean Production) 3 Q C D T Q C T P M J I T J I T T Q C T P M J I T J I T J I T 11.1 JIT 166
J I T 7 750 20 2 000 3 40 ( ) ( ) 167
( 2 ) J I T J I T J I T 168
40 40 3 40 J I T J I T J I T 1. ( ) 2. ( ) 3. ( ) 11.2 ( Takt Ti m e ) 169
A 80 8 8 60 80=6 A 6 6 1 80 Ta k t ( C y c l e Ti m e ) J I T J I T 170
11.3 ( P u s h P r o d u c t i o n ) Muda 171
2 000 2 000 750 100 11.4 (Pull Production) 172
8 4 173
U U 174
11.5 80 8 220 3 20 16 (kosu) 75 2 200 1. 2. 3. M u d a 4. 175
11.5.1 1 9 8 8 ( 3 ) 2 60 1986 2 220 176
335 2. 3 0 370 75 54 11.5.2 1 9 8 8 1992 750 2 000 8 ( ) 7 5 7 750 2 2 177
2 11.6 2 (1) (2) 1 9 8 6 4. 5 1. 8 220 178
7 50 1. 8 1 /17 75 42 40 J I T J I T 179
12
( W I R E M O L D ) ( West Hartford) (Art Byrne) 1 991 9 5 (Frank Giannattasio) 5 40 20 30 25 3 0 5 6 1 J I T 182
6 10 M u d a 183
200 6 184
( ) 6 6 1 400 185
2 6 90 186
(Henry Ford) 30 187
1992 4 4 67 72 24 367 3 14 2 3 1. 2. 3. M R P 5 S M R P 188
50 9 0 4 3 20 40 100 1. 4 367 6 7 100 4 4 200 189
200 200 200 60 2 0 3 4 3 190
4 4 67 3 14 191
1 9 9 5 1 / 2 6 6 500 3 3 50 6 6 5 1991 3 192
1. 20 2. 4 6 2 3. 1993 42 1994 50 4. 80 5. 3 6. 10 10 7. 3 6 8. 400 100 1. 193
2. 3. 194
13
A 65 85 196
M u d a 50 ( ) U J I T 197
13.1 1 9 7 7 20 A 198
4 ( ) 6 10 6 5 5 8 10 10 199
4 5 6 1. 2. 3. Muda 4. 5. 6. 200
A. 1. 2. B. 1. 2. 3. C. 1. 2. 13.2 A. 1. 2. 3. ( ) B. 1. 201
2. 3. 4. 5. C. 1. 2. D. 1. 2. E. 1. 2. 3. 1. 2. 3. 4. 202
5. 6. 7. 8. 9. 10. A. / B. 1. 2. 3. 4. ( ) 5. 6. 7. 8. ( ) 9. 10. 11. 13.3 1980 203
J I T / 5 S ( J I T ) 13-1 1993 1995 / / 66.4 55.7 17.9 52.1 32.0 59.3 43.5 54.1 29.4 57.0 95.0 71.7 45.9 34.0 204
( ) 13-1 A. 1. 2. 3. B. 1. ( F M E A ) 2. 3. 4. C. 205
1. 2. 3. 4. D. 1. 2. 3. 4. E. 1. 2. 3. F. 1. 2. 3. G. 1. 2. H. 1. 2. 85 206
207
C1 MK M K 3 70 17 M K 5 11 210
M K ( ) M K M K M K M K 211
M K M K M K M K 5 M K 50 p p m ( ) 212
M K M K MK M K 4 M K 1994 8 4 213
214
C2 1955 42 1971 26 C2.1 6 25 215
10 1 5 (Michael Eisner) ( ) 1 500 (Standard Operating Procedure, 216
S O P ) 37 000 37 000 1. 2. 3. 4. 5. 6. 7. ( ) S O P 217
C2.2 C2.3 218
( ) ( ) 219
1 220
C3 5 S 1 360 ( ) 221
10 3 222
1. ( 5 S ) ( ) 2. 1. 5S 2. 3. 4. 223
C4 150 224
1 9 8 8 225
226
7 : 30 1 15 1 9 9 5 7 227
1994 228
( ) ( 3 3 229
3 230
10 4 5 231
M u d a M u r a M u r i ( ) 6 1 / 4 232
C5 (Désiré Demeulenaere) 5 S 5 S 10 233
1/3 12 234
C6 5S (Désiré Demeulenaere) 5S 5S 1 500 6 5 235
5 S 5 S 5S 14 000 1 500 1 500 500 14 000 5 S 14 000 1 000 14 236
3 2 000 5 S 237
C7 200 5S 100 20 120 300 238
300 5 4 5 239
5S 240
C8 M u d a (Commerce City) ( S U N C L I P S E ) (Gene Shelton) ( ) Muda C8.1 ( o p p o r t u n i t y - f o r- i m p r o v e m e n t, O F I C 8-1 (Customer Satisfaction Form) ( C 8-2 ) 241
O. F. I. # C8-1 242
# / / ( ( / ) ) C8-2 243
C8.2 ( Q I T ) C8.3 Muda ( S t. H a r t D i v i s i o n ) ( M u d a ) ( P a t A r n o l d ) M u d a M u d a C8.4 (Kent H. Landsberg ) (Orange Division) 244
(Stacey Snyder) ( ) M u d a C8.5 245
80 700 ( ) 289 246
C8.6 Q Q Q (OFI) ( Q I T ) Q 5 (Greg Brower) 247
20 380 Q 19 248
C9 ( E x c e l ) 6 O E M O E M 4 000 10 20 (empow-erment) C9.1 1992 3 1993 3 3 3 249
15 57 73 78 44 ( P D C A ) ( C 9-1 ) (1) (2) ( ) ) ( C 9-2 ) 250
C9-1 PDCA C 9-2 251
C9.2 2000 9 2 ( ) 5 3 4 10 1 500 2000 700 ( S P C ) 252
E C9-3 E C9-3 2000 A. 1. 2. 253
3. B. 1. 2. 3. C. (SDCA) 1. 2. 3. D. (PDCA) 1. 2. Muda 3. Muda(muda walk) 4. 5. 9 S D C A P D C A 2000 254
C 9-4 K TA * 0 1 1 2 3 4 5 6 7 8 5 S 2 * C9-4 255
C9.3 2000 ( ) 2000 C9.4 256
2000 257
C10 ( L E Y L A N D ) 1993 ( L a n c a s h i r e ) D A F BV (John Olive) DAF BV ( K a i z e n ) ( l e a n ) 1 9 9 5 2 0 80 5 258
C10.1 (1) (2) (3) C10.2 1 9 8 9 D A F 259
( ) 101 1986 28 1 995 4 ( C10-1) C10.3 42 30 5 0 260
20 C10.4 C 1 0-1 261
C10.5 10 19 262
30 263
100 83 C10.6 80 8 2 264
18 C10.7 (1) 265
(2) ( 3 ) 6 1 2 3 45 50 4 5 6 C10.8 266
10 / 25 267
T C10.9 1989 268
C10.10 269
C 11 ( O ff e n b a c h ) (Löbr & B r o m k a m p ) ( L ö b r o ) G K N 1 800 ( T P M ) 1989 1992 10 20 102 1 9 9 0 50 35 270
1991 2 7 6 4 ( T P M ) ( J I T ) 1 9 9 2 1992 9. 5 1995 4. 7 25 10 000 1 9 9 3 10 1994 ( T P M ) T P M T P M T P M L Ö M I S 4 271
Löbro( ) Mitarbeiter( ) Instandhaltnug( ) System( ) LÖMIS TPM 6 6 LÖMIS T P M 6 0 L Ö M I S T P M L Ö M I S ( C 11-1 LÖMIS ) LÖMIS 9 6 2 9 3 L Ö M I S 108 16 1 LÖMIS 5S 272
L Ö M I S LÖMIS LÖMIS C 11-1 LÖMIS 273
C11.1 1 9 9 0 1 9 9 5 5S, JIT TPM 0. 15 8 ( 6 1995 ) 90 0.8 5 30 40 (Michael Beseler) 274
1 800 A Z A B C C11-2 (TQC) 6 ( T E P ) ( T P M ) ( T D S ) 275
( T D C ) ( T P S ) ( T P C ( ) T E P T P M T D S T D C T P S T P C C 11-2 6 276
C11.2 ( T P M ) / T P M T P M 277
C12 (Siemens Oostkamp) 44 1992 4 (1) (2) (3) ( 4 ) 1993 5S 278
C 12-1 C12-1 1992 5 320 1995 3 720 1993 1994 10 1992 25. 1 1995 24. 8 5 33 1992 1993 78 1994 1995 83 279
C12.1 (Reinhard Straihammer) (Peter Te u f e l ) ( ) ( ) 6 ( S M E D ) ( J I T U ) 4 1. 280
2. 3. 4. C12.2 ( ) 4 C12-2 281
( C 12-2 ) C12.3 70 1996 1 5 S 120 49 3 282
ABS( ) 12 3 3 5 S 283
C13 (1) 5 (2) 5 ( Tres Cruces) 1993 1 1 994 5 27 78 / 1 3 ( 100 ) 1993 52 33 15 284
1. 2. 1. 2. C13-1 ( ) 285
C13-2 ( ) 286
287
4 ( C13-1 C13-2 ) C 13-3 4 ( C13-4) C 1 3-5 C13-4 4 288
289
C13.1 10 1. 2. 3. 4. 5. 6. 7. 8. 9. C13-6 290
10. 1 9 9 4 5 ( C13-6) C13.2 C13.3 C13.4 291
( ) 1994 79 1995 60 292
( ) ( 167 ) 1994 1995 293
C14 22 420 127 180 ( ) C14.1 1 9 9 5 ( ) ( H e i n r i c h ) 330 300 29 1 ( 294
C 14-1 ) C14-1 1. 2. 10ml 3. 4. 5. 6. 295
7. 8. 500 c c 30 296
C14-1 C 1 4-1 1 9 9 1 63 522 8 8 ( 0. 1 4 ) 2 1 ( 0. 0 3 ) 2 7 ( 0. 0 4 ) 1 9 9 2 72 082 1 0 9 ( 0. 1 5 ) 5 5 ( 0. 0 8 ) 3 4 ( 0. 0 5 ) 1 9 9 3 73 240 1 4 7 ( 0. 2 0 ) 7 5 ( 0. 1 0 ) 1 4 ( 0. 0 2 ) 1 9 9 4 71 792 1 0 5 ( 0. 1 5 ) 4 9 ( 0. 0 7 ) 1 7 ( 0. 0 2 ) 1 993 839 41 2 3 1 7 1 0 9 C14.2 1983 C 14-2 297
C14-2 1983 10 127 1985 18 132 1990 23 282 1995 41 429 189 X 298
1994 16 1 2 1 1995 A 3. 5 B C 299
D 300
C15 (Molinos Rio de la Plata) ( M ATA R A Z Z O ) ( B u n g e & Born) 5 6 6 ( ) 3 6 7 10 1 4 4 2 2 ( ) 4 6 7 11 22 ( 88 ) 35 301
( ) ( ) 1 5 3. 5 2 302
6 18 70 1 ( ) 2 45 303
C16 ( A l p a rg a t a s ) ( N i k e ) 4 2 ( Tu c h m a n ) 200 2 8 ( ) 8 1 2 3 5 4 ( ) 5 304
6 7 8 ( P D C A ) 1 5 P ( ) 6 D ( ) 7 C ( ) 8 A ( ) 1994 6 3 3 3 305
1 2 ( C16-1) 3 ( C16-1) 4 ( C 16-2 ) ( ) 5 ( C16-2) 6 ( C16-3 C16-3) 306
7 8 C16-1 1 9 9 4 7 1 8 1. 3 7 7. 5 8 0 2. 1 9 4. 0 8 0 3. 2 7 5. 5 8 0 4. 3 3 6. 5 8 0 5. 5 4 11. 0 8 0 6. 2 3 5. 0 8 0 7. 4 7 9. 5 8 0 8. % 34 7. 9 80 307
308
309
C16-2 6 m m 9 m m ( 80 ) 12 ~ 15 m m 3 310
C16-3 7 3 7 7. 5 7 1 9 4. 0 5. 6 2 7 5. 5 2. 0 3 3 6. 5 4. 0 5 4 11. 0 9. 5 2 3 5. 0 1. 0 4 7 9. 5 8. 1 % 34 7. 0 5. 4 1 9 9 4 7 60 7% C16-3 311
C16.1 8 8 C16.2 3. 4 22. 5 ( 312
1 1:1) C16.3 : 313
C17 ( I n f o t e c ) 1993 1 9 9 3 1. ( ) 2. ( ) 3. ( RT F s ) 4. ( ) 5. ( ) RTFs 10 314
1996 8 1 0 RT F s 1 993 15 8 4 4 4.5 1993 13 1994 14 1995 12 1994 20 90 10 150 315
5 RT F s ( Vittorio Neri) C 17-1 C 17-1 C 17-1 RT F s RT F s RT F s 316
317
C17-1 318
( E D P ) (Bill Conway) 1995 7 ISO 9000 6 3 319
C18 3 320
( F i d e l i t y ) 1946 ( F i d e l i t y ) 2 2 0 (Edward C. Johnson III) 1980 (USA To d a y ) (Fortune Magazine) 1987 321
322
, ( ) 323
1 9 9 5 (Fidelity Exchange) 324
10 100 1994 9 12 ( 6 ) 1989 325
S T R I D E S STRIDES S (Situation) T (Target) R (Research) I (Implementation) D (Do it) E (Evaluate) S (Standardize) 326
C18.1 ( P M I ) P M I P M I P M I / PMI C18-1 3 327
P M I / / P M I P M I (1) (2) (3) PMI 328
1. 2. 3. 24 4. 5. 6. 7. 8. 9. 5 10. 11. 12. 13. 14. 15. 16. 17. 329
18. C18.2 C 18-2 C18-2 ( ) ( ) 9 ( ) 330
75 5 331
(Ned Johnson) 332
C19 ( L u c a s ) ( K o b l e n z ) A B S 1995 1 800 1994 9 (Gunter Schiele) 1994 4 1995 1996 C 19-1 1994 9 1995 1995 1996 1 994 4 10 6 ( C 19-2 ) 3 5 7 M u d a 333
334
335
M u d a ( ) 1994 1994 120 1 9 9 5 ( C 19-3 ) 8 ( ) 1995 5 ( ) 5S 1995 50 6 0 1 995 400 1 9 9 5 ( C 19-4 ) 336
337
338
1995 7 60 22 339 55 74 3 25 15 40 2 97 35 65 +115 +115 3 1 48 C19-5 3
1995 7 32 2 114 74 10 95 80 340 2 30 40 15 50 C / B 1 48 C19-6 C / B
1995 7 50 90 90 341 478 419 9 3 4 103 4 90 12.5 3 4 14 80 10 90 77 15 14 C43H C19-7 C 43 H
C 1 9-5 C 1 9-6 C 1 9-7 C 43 H 9 3 4 3 4 342
C20 (La Buenos Aires, LBA) L B A 1987 24 L B A 24 LBA 1988 70 L B A 24 L B A 343
C20.1 L B A L B A LBA C20.2 1987 48 15 15 L B A L B A C20.3 L B A 1 9 9 2 3 1 7 5 344
5 000 LBA 24 ( ) C20.4 1 9 9 3 L B A L B A L B A 15 35 24 2 6 900 1994 L B A L B A 345
2 13 L B A 13 LBA C20.5 1994 7 1 8 L B A AMIA(Asoc Mutual Israelita Argentina) 94 190 L B A 22 130 160 L B A ( F e r n a d o C o l e t t i ) 1 991 ( ) 346
50 347
L B A 24 L B A L B A 348
83 92 L B A, L B A LBA L B A 1993 LBA 349
C21 A (Jean Labadie) A ( J I T ) ( T P M ) A A C21.1 3 5 S 145 350
6 4 4 3 ( ) 5 S ( ) 351
26 0 6 2 3 3 C21.2 1/4 1 / 4 1987 6 (Overall Efficiency Rate) 1993 3 T P M 1/4 352
1 / 4 1 / 4 1 9 9 4 1 0 1 / 4 86 1994 3 1 / 4 3 1 0 1 994 6 1 / 4 1 / 4 1 994 9 7 200ppm 20 p p m 5 353
1. 500 4 500ppm 2. 50 2 000ppm 3. 8 2 700ppm 4. 5. 1 / 4 354
1995 9 75 p p m ( ) 1995 12 20ppm C21.3 ( 10 ) 355
1993 3 356
C21.4 ( P D C A ) P D C A R 20 P D C A P D C A 75 357
P D C A A ( ) C21.5 1 9 9 3 9, P D C A P D C C21.6 358
1 0 6 1 0.5 2 0 359
T P M ( ) C21.7 1 / 4 360
361
A
( K A I Z E N I N S T I T U T E ) P M 364
Kaizen Institute (Japan) MY Akasaka Bldg., 3F 2-11-15 Akasaka Minato-ku, Tokyo 107 Tel: 81 3 5563 9391 Fax: 81 3 5563 9381 E-mail: gemba@kaizen.co.jp Kaizen Institute (Germany) Königsberger Straße2 60487 Frankfurt/Main Tel: 49 69 953012 0 Fax: 49 69 953012 17 E-mail: 101553.3624@compuserve.com Kaizen Institute (France) 54 Boulevard Saint-Jacques 75014 Paris Tel: 33(0) 1 45 35 66 44 Fax: 33(0) 1 45 35 65 64 E-Mail: 101623.710@compuserve.com Kaizen Institute (UK) 365
4 Tavistock Place London WC1H 9RA Tel: 44 171 713 0407 Fax: 44 171 713 0403 E-mail: 100343.257@compuserve.com K a i z e n Teaching International Coordination Off i c e (Switzerland) ZurcherstraBe 4 8852 Altendorf Tel: 41 55 451 19 40 Fax: 41 55 451 19 49 E-mail: 101553.3626@compuserve.com Kaizen Institute (USA) 930 South Mopac Barton Oaks Plaza Building II, Suite 530 Austin, TX 78746 Tel: 1 512 261 4900 Fax: 1 512 328 5749 E-mail: kmkad@mailaustin.computize.com Kaizen Support AB (Sweden) Bredgrand 2 S-111 30 Stockholm 366
Tel: 46 8 790 50 35 Fax: 46 8 790 50 45 Kaizen Institute (Spain) C/Provenza, 288 Pral. 08008 Barcelona Tel: 34 3 487 23 42 Fax: 34 3 487 96 76 STRAT (Argentina) Av. Cordoba 1255-Piso 4 1055 Buenos Aires Tel: 54 1 815 9652 Fax: 54 1 815 9658 ABG International (Mexico) A. De Cossio # 105-90 Piso A Col. Tangammanga, S. L. P. 78269 Tel: 52 48 17 94 81 Fax: 52 48 17 94 27 367
B
(1) Acceptable Quality Level A Q L (2) 5 Ask why five times (3) Check gembutsu (4) Conformance (5) Control Chart (6) Cost Q C D M u d a ( ) (7) Cross-functional management QCD (8) Cycle time ( 370
Takt time) (9) Delivery Q C D (10) Don't get it, don't make it, don't send it Q C D (11) Failure Tree Analysis FTA (12) Five golden rules of gemba management (1) (2) (3) (4) (5) (13) 5M Five M's M 5 ( M a n p o w e r ) 371
( M a c h i n e ) ( M a t e r i a l ) ( M e t h o d ) (Measurement) (14) 5S Five S's S S e i r i ( ) S e i t o n ( ) S e i s o ( ) S e i k e t s u ( ) S h i t u k e ( ) S o r t ( ) S t r a i g h t e n ( ) S c r u b ( ) S y s t e m a t i z e ( = ) S t a n d a r d i z e ( ) 5 C Clear out( ) Configure ( ) Clean & check( ) C o n f o r m ) Custom & practice( ) (15) Flow Production (16) FMEA F M E A ( FMAA) (17) Gemba (18) Gembutsu 372
(19) Go to gemba ( ) (20) Heinrich's Law =1:29:300 29 300 (21) Hiyari KYT(Kihen-yochi training) K Y T (22) Hikari report(scare report) (23) Isikawa diagram ( ) ( ) 7 (24) 9000 (ISO 9000 Series Standards) 373
(25) Jidhoka(Autonomation) JIT (26) Jishuken Gemba Kaizen 6 0 ( J I T ) JIT (27) JIT (Just-in-time) M u d a ( ) ( Toyota Produition System) ( L e a n produition system) (Kanban System) (28) JK(jishu kanri) (29) Kaizen concepts 1) 2) 3) PDCA SDCA 4) 5) 374
6) (30) (Kaizen Story) (31) Kaizen systems 1) (Total Quality Management) 2) (just-in-time production system) 3) (Total productive Maintenance) 4) (Policy Deployment) 5) (Suggestion System) 6) (Small-group activities) (32) Kanban (33) Kosu 375
(34) Morning market ( ) ( ) (35) Muda Muda( ) M u d a Q C D M u d a (36) Mura (37) Muri (38) One-Piece flow Muda (39) Pareto chart (J. M. Juran) 80 : 20 376
8 0 20 7 (40) PDCA Plan-Do-Check-Action ( ) (41) Pull Production (42) Push Production (43) QA Best-Line Certfication (44) QCD (Qualiy, Cost, Delivery) Q C D (45) QCDMS M ( M o r a l e ) S ( S a f e t y ) QCD (46) QFD(Quality Function Deployment) 377
(47) QS 9000 ISO 9000 ISO 9000 QS 9000 (48) Quality Q C D (49) QCC(Quality Control Circles) ( 10 10 ) (50) SDCA Standardize-Do-Check-Action QCD (51) Q C D Simultaneous realization of Q C D 378
(52) Small-group activity 5 ~ 10 ( T P M ) (53) Standardization (54) Standardized work (takt time) (55) Standards SPC (56) Statistical process control (57) Store room (58) Suggestion System 379
(59) Takt Time (60) 3K ( K i k e n ) ( K i t a n a i ) ( K i t s u i ) Q C D (61) 3M M u d a ( M u d a ) ( M u r a ) ( M a r i ) (62) 3M Three M's (3M) in gemba ( M a n p o w e r ) ( M a t e r i a l ) ( M a c h i n e ) ( M e t h o d ) (Measurement) 5M enance) (63) T P M ( Total productive maint T P M 380
T P M 5 S TPM (64) Total Quality Control TQC T Q M ( To t a l Quality Management) T Q C (65) Two-day gemba kaizen (66) Value Analysis 1947 (L. D. Miles) ( ) VA (67) Value Engineering VE 1 9 5 4 VA V E 381
( ) (68) Visual Management 382