What is Kamishibai?

 Enhancing Gemba Walks with Kamishibai: A Process-Oriented Approach

In Lean management, Gemba Walks are a valuable tool for identifying inefficiencies and promoting continuous improvement. To further enhance the effectiveness of Gemba Walks, the Japanese auditing method known as “Kamishibai” can be incorporated. Kamishibai allows for structured mini-audits within the workplace, providing an organized and process-oriented way to ensure that standards are consistently met and deviations are corrected.

This blog will explore how Kamishibai can be integrated with Gemba Walks, explaining the tools involved and the impact they can have on workplace auditing and accountability.

What is Kamishibai?

Kamishibai, meaning “paper play” in Japanese, is a visual management tool used in Lean environments to conduct quick, efficient audits of workstations and processes. It serves as an auditing system, structured around the use of a planning board, T-cards (which have red and green sides), checklists, and a 3C list for documenting concerns, causes, and countermeasures.

The method is simple but highly effective, enabling teams to regularly audit different processes and identify areas for improvement. Kamishibai is most often used in manufacturing environments, but it can also be applied in other industries to uphold standards and ensure that processes run smoothly.

Organized Auditing: The Structure of the Planning Board

The planning board is at the heart of the Kamishibai system. This board is divided into two sections:

• Left Side: This side of the board holds T-cards for audits that are pending or scheduled.
• Right Side: Once an audit is completed, the T-card is moved to the right side, where the outcome of the audit is recorded.

Each T-card represents a specific process or audit topic, such as “5S” (sort, set in order, shine, standardize, and sustain) or “standard work.” During each audit, the auditor uses a series of questions or checks on the card to verify whether the standards are being met.

Gemba Accountability: Utilizing Checklists for Auditing and Improvement

As part of the Kamishibai method, checklists are often kept at workstations. These checklists serve as a record of which audits have been conducted and highlight areas where improvements are needed. The visual nature of the checklists makes it easy for employees and managers to see which workstations may need additional attention during Gemba Walks.

When an audit yields positive results (i.e., all standards are met), the T-card is flipped to its green side, indicating success. If any standards are not met, the T-card is flipped to its red side, signifying that corrective action is needed. In this case, the red-side T-cards are transferred to the 3C list, where the following steps are documented:

1. Concerns – What issue or deviation was observed?
2. Causes – What is the root cause of the problem?
3. Countermeasures – What actions need to be taken to correct the issue?

This structured process ensures that issues are not only identified but are also followed up with concrete actions to prevent recurrence.

Enhancing Gemba Walks: The Role of Kamishibai Cards

Kamishibai cards are an excellent complement to Gemba Walks. During a traditional Gemba Walk, managers visit the “Gemba” (the place where the work is done) to observe operations and talk with employees. While these conversations are valuable, Kamishibai cards provide a more structured framework for discussing key process areas and standards.

For example, during a Gemba Walk, a manager might select a Kamishibai card focused on “5S” principles. The card would contain questions such as:

• “Are items frequently stored in the same spot?”
• “Is the workspace tidy and free from unnecessary clutter?”

These targeted questions guide the discussion, ensuring that the walk remains focused on key operational standards rather than veering off-topic. This approach also helps identify specific areas where improvements can be made, encouraging continuous adherence to Lean principles.

Continuous Improvement Through Kamishibai

Kamishibai is more than just an auditing tool—it’s a method for promoting a culture of continuous improvement. Because Kamishibai audits are conducted regularly, employees are always aware that their processes will be reviewed, encouraging them to consistently adhere to standards. Moreover, the red-green T-card system provides an easy-to-understand visual indication of which areas are performing well and which require attention.

This system also fosters accountability. Since every deviation is documented on the 3C list, there is a clear path from identifying an issue to taking corrective action. Employees are empowered to participate in this process, making suggestions and helping to implement countermeasures.

Finally, Kamishibai audits are flexible and dynamic. The audits can be adjusted over time as new processes are introduced or as existing processes evolve. This ensures that the auditing system remains relevant and continues to drive improvement.

Conclusion

Kamishibai is a powerful tool for enhancing the effectiveness of Gemba Walks by providing a structured framework for conducting mini-audits and addressing deviations. The method helps ensure that operational standards are consistently met, fosters accountability, and encourages continuous improvement across the organization.

By integrating Kamishibai into your Gemba Walks, you can create a more focused, efficient, and process-oriented approach to workplace auditing. This not only helps maintain operational excellence but also empowers employees to actively contribute to the ongoing improvement of their work environment.

Kamishibai is an essential component of a well-rounded Lean strategy, offering a practical way to keep teams aligned with organizational goals and quality standards. With regular audits and a structured process for addressing issues, Kamishibai helps businesses build a culture of excellence that drives long-term success.