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Lean Six Sigma Essentials

  • DMAIC Roadmap
  • System Interaction Map

01 DEFINE

  • VOC Translation Matrix
  • CTQ-Tree
  • Kano Model
  • Is/Is-Not Method
  • SMART Goals
  • SIPOC
  • In/Out-Frame
  • Stakeholder Matrix
  • Cost of Poor Quality (COPQ)
  • DMAIC Milestone Plan
  • Project Charter
  • Define Tollgate Checklist

02 MEASURE

  • Parking Lot
  • Detailed Flowchart
  • Swimlane Diagram
  • Y=f(X) Cascade
  • Data Collection Plan
  • Sample Size
  • Measurement System Analysis
  • Chart Selection Guide
  • Brown Paper Approach
  • Baseline & Sigma Level
  • Measure Tollgate Checklist

03 ANALYZE

  • Fishbone Diagram
  • 5S Quick Wins
  • Spaghetti Diagram
  • Work Sampling (MMA)
  • Yamazumi Chart
  • Scatter Plot & Correlation
  • 5 Whys
  • Affinity Diagram
  • Pareto Analysis
  • Interrelationship Diagraph
  • FMEA
  • Hypothesis Test Selector
  • Analyze Tollgate Checklist

04 IMPROVE

  • 7 Wastes (TIMWOOD)
  • Standard Operating Procedure (SOP)
  • Poka-Yoke
  • SMED (Quick Changeover)
  • Kanban (2-Bin System)
  • Brainwriting 6-3-5
  • SCAMPER
  • Pick Chart
  • Pugh Matrix
  • Pilot Plan
  • Rollout Plan
  • Improve Tollgate Checklist

05 CONTROL

  • Control Plan
  • Control Chart (SPC)
  • Visual Controls
  • Kamishibai
  • OEE & TPM
  • Handover Checklist
  • After Action Review
  • Final Tollgate Checklist
View Categories
  • Home
  • Resources
  • B303 Lean Six Sigma
  • 05 CONTROL
  • Kamishibai

Kamishibai

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Audits that people look forward to? KamishibaiA visual daily audit system using cards (Green/Red) tied to a board, turning auditing into a predictable, supportive routine. Click term for full definition turns checking into a short, supportive daily routine that keeps the new standardThe finalized way of working after rollout — documented, trained, and physically reinforced, so the improvement becomes routine. Click term for full definition alive. Watch the short video, then work with the toolkit PDF: it explains the method, shows a worked example and gives you a blank template to fill in.

Tool video

The short tool video will appear here.

Kamishibai in short

  1. Pick the checks. Take the critical points from your SOP and Control PlanA living document defining what's controlled, how it's measured, its boundaries, and the reaction plan if it goes out of control. Click term for full definition. One check per card.
  2. Make the cards. Green on one side, red on the other. Location and question on both.
  3. Set the rhythm. Daily, weekly and monthly cards. Assign leaders to each layer.
  4. Do the walk. Pick a card, go to the spot, check, flip to green or red.
  5. Close the red. Every red card gets an action and an owner. Review the board in the shift meeting.

Key points

  • One card, one check.
  • Leaders on the floor, every day.
  • Red triggers support, not blame.
  • Simple, visible, physical.

Related tools: Visual Controls · Standard Operating Procedure (SOP) · Control Plan

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