Monozukuri Kata
Driving Continuous Improvement to the Max
Makigami Systemic Process Improvement
Makigami is:
A structured process Mapping- and Improvement method, supporting systemic process improvement in physical (visible)- and invisible processes.
With Makigami you create optimal Value Adding processes with the know how of your own crew.
What Is Makigami?
Makigami is -at first- a Process Mapping technique
Makigami literally means: ‘Role of Paper’ in Japanese.
But it is also the ‘Action Script’ to the Ninja (who holds this as role of paper in front of him).
It contains ‘the Golden Rules’ –the basic principles– the actions that really matter…
Makigami can improve ANY process in ANY environment
Offices, hospitals, laboratories: any place where processes are not directly visible or physical.
Makigami is a Team Tool
People working in your company know what’s going on, what works and what doesn’t. No expert can ever reach this level of company specific knowledge. By structuring the companies knowledge the impossible becomes possible!
Makigami leads to Breakthrough Improvements
Makigami is not a kaizen tool. It is a kaikaku tool: It results in large breakthrough improvements. The ‘Future State’ process can be continuously improved further by kaizen activities.
Will Makigami suite your needs?
Fundamental improvements without Capital Investments
Kaizen is about Small Steps… Makigami about breakthrough changes.
Regular or VERY special business… Makigami will work for you.
Your own people are the experts. Use their expertise, but use it in the correct way.
First simplify and stabilize your processes before implementing (more) software. Software can cope with QUANTITY, where makigami delivers QUALITY of the process.
If you dare to take a leap, makigami will visualize, analyse and improve ANY business process, involving those who have to do it. Doing it right, you may expect fabulous results.
Where does Makigami Originates from?
Right you see, as far as we know, the first ‘value stream map for offices’. It was made in 1996 by Okumura-san at Fujico (Japan). Compare the size of the door at the left! After 10 years it was still being improved, as we could see during a visit in December, 2006
Okumura San during a Masterclass in Tokijo 2006
The first ever made makigami in 1996 at Fujico (Japan)
This Fujico Makigami could be considered to be ‘The mother of all Makigami’s’.
It was the inspiration to Arno Koch‘s development of the Makigami Systemic Process Improvement methodology. Since 1999 Arno trained hundreds of Instructors.
When you need substantial improvements, fast, sustainable and in any process
Makigami leads to breakthrough changes. It will work in ANY business. It relies on the expertise of your own crew. It does not asks for capital investments It can be done fast. Faster than anything asking for investments.Why Makigami?
Why Makigami? What is the purpose?
The purpose of a Makigami process map, is to visualize, untangle and improve processes where multiple people and/or departments work together More…
What is the result of Makigami? What can be achieved?
Makigami is a ‘kaikaku’ tool: Breakthrough improvement. Halving and doubling. I.e. troughputtime reductions of 90% are common. More…
Where to use Makigami?
Makigami can be used in ANY environment: Offices, hospitals, laboratories: any place where processes are not directly visible or physical. But also visible processes and Value Streams can be analyzed. More…
How long does it take?
The analyses can be made within one week. The implementation can be done in 100 days. More…
How to perform a Makigami Analysis
> 90% of your resources may not add any value…
Makigami will reveal the huge hidden opportunities
The vast majority of all processes use less than 5% (!) of the time adding value! This means there is a huge potential for improvement. Why not use it before the competition does…?Select a process that will have a leverage when improved
Define a REALLY ambitious target to be achieved
Bring a team together with 360 degree view on the process
Allow the team to do the full analyses as described below
Let the team present their proposed new process, and its implementation plan for the next 100 days
Ask what the team needs to fulfill its proposal
Give the team a GO and set a presentation-date for over 100 days
1. Draw Current State
What is the situation NOW? Who does what and when? Who communicates to who and how? What does the time-line look like? Which documents and systems are being used?
Find out what really happens in the organisation!
2. Make Loss Analysis
From each and every activity in the current state, determine: Does this somehow creates any VALUE? Do machines run better? Does it make the customer happy? Is it a legal obligation?
Find out what really matters. And what not!
3. Draw Future State
Based on the learnings now done, design the optimal process. Only create value, eliminate ANYTHING that does not contribute to your goals.
Find out how to create a process (and organisation) that only creates value, without doing thinks bring no value at all!
4. Make 100 Days Plan
‘The difference between a dream and a goal is a plan’.
The team has commitment, know-how and a plan how to create the new process. Now the commitment and support of the management is needed.
Find out what everybody needs to create a huge success!
Process Improvement Booster Week
After our long years experience, we enhanced the application of the technique. As a result, it is now possible to make quite deep analyses of the current state and redesign for the future state, within as little as one week.
In such ‘booster-weeks’, up to 6 simultaneous cross functional teams can analyse up to 6 processes. At the end of the week, they each present a 100-day implementation plan.
The participants will learn the Makigami-method, working on their own business process.
The proposed new way of working is presented to all stakeholders. and the formal ‘Go’ to implement is given.
After a successful one week ‘makigami workshop’, the teams proudly present their findings and results and request the ‘Go’ for implementation.
Continuous Improvement Programs
Makigami can perfectly be used in any improvement programbut gains the best results in Botom Up environments like:
Lean Manufacturing
Strong focus on ‘Flow’: creating processes that create value whenever the customer needs it
Total Productive Manufacturing
TPM is a strongly Equipment focused Improvement Strategy: Have reliable equipment creating value
Six Sigma
Uses statistical methods to create Stable Processes that produce low deviations and thus less out-of-specs
Monozukuri
Combines the technical aspects from Lean, TPM and Six Sigma with the Social aspects of the system
Improvement Information
Process Design
The Makigami Technique is easy. But designing a good process isn't. Here is some help.
Leadership
It takes courage and trust to lead an organisation to its Future State. Leadership at its best.
Tools Glossary
The world is full of nifty tools. But what are all those Japanese things? Here is an overview.
Workshops
You can do it yourselves. And with a good trainer you will learn a lot AND have a guaranteed result!