Saturday 17 November 2018

Empowering Potential Employees Through Kaizen and Problem SolvingAbility

 Empowering Potential Employees

Genba, as popular term that many touted after the "Kaizen" for the perpetrators of the industry nor the Government ditatanan Japan in the concept of effective field management and systematic way. The term Genba in the context of the industry can be defined as a work place that is a realistic place does good and bad which a value-added work processes can be performed.

In the service sector services, "gemba" is the place where consumers make contact with the service offered. Similarly, in the system of governance, "genba" can be arranged as a place where the authorities/government agencies do a service to the community or the location where a building project is done. In this paper a description of understanding restricted the workplace in understanding in the field of industry.

concepts of work area management

Various concepts of work area management practiced since introduced by Taylor until the inception of field management concept initiated by Taichi Ohno, known as the Toyota Production System (TPS). The concept of a work area management management based TPS or "lean management" known by the term "Genba Kanri" are among the Western management is referred to as "the Workplace Management".

The sense of the word "kanri" in English originally meant Japan manage the laws of nature and then along with the development of operational management systems company based lean (lean) were pioneered by Toyota as the company successful pioneers applying the concept of management the workplace, then the word "kanri" translates in terms of "management".

Business competition

The tight business competition in an attempt to improve performance with operates on low operating costs without neglecting the quality of product/service as an efficient company requirements with operates on empowerment potential employees through continuous improvement with action to combat a problem that is fast, has spurred many companies focusing management operations management is effective in the production through the application of the system of "the Workplace Management".

As the doctrine of the management the management of work in the field-based groups to facilitate the range of control in ensuring smooth production processes management should be supported with employee development through intensive coaching in addressing the standard work system. Any problems that arise should be identified with either the transparent to angulation quickly places where problems that occur (genba), while finding the root of the problem through the newspaper method of problem solving quick, do areal work with systematic way and approach so that the same problem transparent not repeating.

Standard process

To ensure the stability of the standard process for the creation of a good product completes on schedule, the required review process based audit regularly early in identifying the problem as to corrective actions. This requires a management approach that provides skilled employees with support to Excel in the conduct of their daily work with emphasis on discipline training as the Foundation so as to encourage them to be employees who have good performance based standard.

The effectiveness of application of workplace management, as do many companies Japan starts from the creation and empowerment of small working groups commonly referred to as "Small Company" that comprises 8 -12 people. A working group was formed in a structured and led by a group leader/team leader/supervisor responsible for changing mindsets member group with empower team members values-based corporate culture through discipline to the process management process work that standardized.

Target characters

In optimizing the achievement of target characters a workplace leader should be oriented towards "Continuous Improvement" in optimizing the achievement of vision and any existing working groups, in order to meet the targets defined by the scope of management success standard indicators include; Delivery, quality, Cost, Safety and Moral (QDCS).

Workplace management implementation process relying on the align method that is right for the right scenario in accordance with the conditions and company culture based on that substance through application management point out on workplace 3 important factors that consists of 3 g (Genba, Genbutsu, and Genjitsu);


(1).: it is a fact (a real place) where added value is created to meet the request of the customer. Workplace management must be designed in an effective workplace management with system-based approach working group (working group) headed by the Chairman of the group. Group leader/team leader and Manager should be someone who understands the circumstances in gemba directly.

(2) Genbutsu: Genbutsu (real think) Japan means a real physical condition and the fact that covers the State of products, materials, parts, processes and machine tools used. When the production element is not running properly or cause problems then a menage must go to genba (go & see) to see, understand, pay attention to and study the problems that actually happened. By developing the habit of going to the gemba (go and see), corporate leaders will have the confidence to use it in solving the specific problems quickly.

(3) Genjitsu: Genjitsu (real fact) means the actual situation or the real facts that are not shaped the theory. When does the process of visually viewing genbutsu problems there then it should be followed up with an effort to find out more details by examining every potential causes to find out the root of the problems in fact. We need to constantly ask yourself ' why ' by looking at the process of the work done and ensure that the measuring instrument & data that we get has been accurate.

Initially, the introduction of genba kandri (workplace management) is designed to be operated by people who are ' doing ' the work and not the people who manage the ' job. This enables team leaders and operators to understand the performance of a company in the context of performance-based production process each group work with highlight combat problems that appear as action where change needs to be done through identifying the root of a problem.

The Essence Of The Workplace Management

Though many alternatives in the setting of important elements in the implementation of the management, but the majority of the workplace companies worldwide level based lean management specify the most essential element in the implementation of the application of the concept of "New Workplace management "includes the following:

  1. The vision of the target achievement-based value.

Every company must have the vision and forward supported by the values of the company/organization as a strong grounding in the running of its activities. A value of no will mean without a strategic and systematic action to form a strong corporate culture. The company's values must be built that rises up to touch the order leadership group that are in the path of the workplace area.

This is very important because of the urgency, the value should always be addressed as generate spit and adhesive intact in running the company's operations. So the importance of the values underpinning the achievement of company vision as directions for workers who want to identify emotional and demanding them to do his work with a high sense of belonging. By knowing the purpose and the way how to satisfy its customers through appropriate value adjustments of vision can change the behavior of its members in completing the job with great meaning and maximum results.

Workplace Management

In the success of the application of Genba kandri (Workplace Management) in the context of TPS in Toyota's example, the vision that became the cornerstones of values that must be applied in addressing daily work can unify employees ' insights in to behave to achieve the targeted goals include:

(1) Challenge (Challenge): maintain a long-term vision and strive to meet all challenges with the courage and creativity needed to realize that vision;

(2.) Kaizen, which means striving for continuous improvement. Because it is not a process can be expressed perfectly forever, there is always room for improvement.

(3) the Genchi Genbutsu : Go to the source of the occurrence of problems in order to find the facts to make correct decisions, build consensus and achieve goals.

(4) Respect (respect): respect for others as an effort to understand the other person, accept responsibility and do our best to build up mutual trust.

(5.) Teamwork (cooperation): stimulates personal and professional growth, shares opportunities for development and maximize the performance of individuals and teams.

  1. Training & teaching (training & teach people).

The success of an effective management system and prospective in the area of the headwaters of the workplace readiness resources through progressive training approaches and referral (coaching) of leaders of working groups should be made directly shots that are arranged in a planning a sustainable resource development.

A typical leader needed in contexts management workplace is teaching other people, no matter how the abundance of skills and knowledge that are owned by someone. Because without the ability to teach, give referrals as a form of character development and mindset, one leader cannot spread his knowledge to others. If the skills and knowledge it has not spread to other people, your company/organization is not going to grow up and worked well.

importance of the correct development

Inspired by Konosuke Matsushita's experience every time make a visit to his client who always get the question "Whether made by  electric? With spontaneous  pioneer Group was always talk about it that " Electric focus to get people (create people) and we also manufacture electrical equipment and various other products"

It is aware of the importance of the correct development of its resources in stabilizing the company's operations. By that time the motto which is the value for the Matsisitha Electric is " Business is rooted in human resources", which means that only by preparing an educated workers, so they can grow and develop as human beings that had been in the business. Therefore, although the products in production by matsuhita important, well done so first of all we should focus to develop the people who do the work.

  1. Kaizen-based working group Leadership

Leadership is a management figure that workplace take responsibility entailed the performance group that is able to translate the vision of the company in the context of activities of the group in the running production process. The leader of the Working Group in this regard is always standing in the forefront of the tiered, ranging from team leader until the group leader who mostly played by a supervisor.

The leadership group is geared to always support the activity of production directly, improving the system of work, identify all the problems that arise and lead change by always giving directives to the fore in developing members his group.

Ability of leading, teaching

This is done because through the ability of leading, teaching with adequate job knowledge will be able to encourage and motivate its members in doing innovation through continuous improvement with transfer capabilities He had to the team in order to achieve the target of daily short term and long term.

The workplace leaders always consistent in analyzing jobs in the area, looking for an efficient way to combine, rearrange, simplify the task in order to produce efficient utilization in manager "material, machinery, labor, the method of work, the working environment, through an approach that mindset always encouraged his subordinates to do continuous improvement of various aspects related to attitudes and aspects of the technique in the work.

Philosophy of Kaizen

In the philosophy of Kaizen, a small improvement is better than a big improvement on that a little bit and then it stops and is not sustainable. Kaizen is how to make in order to make work easier. The method of work that most young does not mean fast and most convenient but the jug must be quick and most conducive in creating good quality. Kaizen is a container to create productivity because it was able to identify and eliminate awkwardness odds and overcoming work such as waste in the process of bending, walking, stretching, reaching, grasping and double handling. but the about working smarter not harder is often not reflected in how we pay people

The effectiveness of a person is a leader on the workplace area based upon the four key performance results is able to reach the indicator success in the production process, namely Quality, Cost & Productivity – Delivery – Safety-morals. To upgrade to the 6 elements of the success of the production would be optimum if the leader of the Group's members are exciting to the workplace to always engage in a process of continuous improvement (continuous improvement) as well as an effective training process.

  1. Regular Communication (Regular Communication)

To ensure effective communication required schedule of meetings (meeting) that the standard to support the implementation of regular communication (rule of communication) and the discussion of the countermeasures of the problem nor the repair fore various levels supporting the activity of the workplace management. Regular communication is very important and affect performance in achieving the desired vision.

On a fundamental level that, an employee who does not know the targeted vision would rarely motivate each person for issue possession and potential employees will not know what to expect especially regarding important information such a presence, passion, performance, productivity and the problem of what is a major issue everyday.

In various surveys that much done in some levels the company concluded that the Working Group to communicate effectively is much more possible and perform well than companies that do not communicate through performance a regular  and ignore the "involvement of employees".

  1. Transparency and visibility

The management of the "you can't manage if you cannot measure" Thus the Act of measurement, the record of achievement, problems appear, the repairs have been things to know by all the teams work as well as anyone who wants to know the performance of a group is generally transparent and visualized.

The information is intended for all information on performance must be updated on information and information, information is always to be observed in the base of the takers.  The recording of the performance is placed on the scoreboard in a must and always accurate and effective working group that is explained by a transparent display by anyone especially a member of the Group and the management.

Visualization in Japanese known as (miuruka) in workplace management in to 2 parts, namely:

Visualization performance & status of a work.

The visualization of the achievement of quantity information (production achievement), quality (quality), Key Performance indicators (KPI). The status of the problem (problem identification status). The process of solving problems (problem solving process), work efficiency, Kaizen (continuous improvement status). The results of inspection / standardized audit work, 5S status inspection, 7 Waste (7 waste). The Status of employees (Employee Status) as Training / Competence Matrix, Training Plan, the latest information that needs to be known by the employee etc.

Visualization of standard work instructions;

Standard work instructions is visualization the direction/guidance elements that interact in the system working in areas such as the workplace; security instructions (safety instruction), a standard work instructions (standard sorting instruction), direction lines move, map the placement of the employee (operator job assignment), Mark the boundary lines (border line), Equipment Identification Labels, label machinery and materials that are informative, etc.

A transparent visualization is a key data in that it should be clearly defined and easily understood to everyone who sees it (informative). Comprehensive data that is visualized is the main reason of the key employees who are always ignored to vision in the work will be given the visual information that is updated at any time and easily monitored by anyone that wants to know.

  1. Gembutsu Genchi (Blusukan/Factory Walk)

Believe it is good and gets better and longer if always wise for a visit to the place of work/events to see clearly and understand the problem or condition against which in fact is taking place.

Terms in management

In the context of the above can be sentences Japan management is termed as Gembatsu Genchi that literally comes from the Japan, i.e., "go and see problems in the field" or "Go and See the Problem". Genchi Genbutsu is not just a theory, but rather emphasizes the practice of doing observation directly to understand (real fact) at the place of occurrence of the problem (a real place) in order to understand that there are as the basis for performing the repair that is accurate, fast and precise.

As an integral part of the Toyota Production System. Genchi Genbutsu like what is this? Taichii Ohno, the inventor of the concept of the Toyota Production System, putting it in a way to distinguish the concept of "data" with "facts". Data and facts have a very big difference. For example, see data about the destruction of a machine by doing a direct observation on the scene is very different. "The Data certainly important within the Organization, but I put the greatest emphasis on the facts." (Taichi Ohno).

  1. The process of Settlement the problem (Problem Solving Process)

The opposite of a problem is an opportunity, so any new problems that occur is an opportunity potentially to make improvements so that the same problem doesn't happen again (repeatedly).

A working group (working group) under the control of the group leader/supervisor acts as a cluster of the most ahead in overcoming any problems occurred by involving all members of the group. Case per case permanence that appears should be recorded on identification of problem solving sheet which is available on the Board results (scoreboard) which can be visually identified and transparent in the "area of small company" that there are each working group

Act of settlements

The Act of Settlement the problem should be a working group of leading group leader to conduct the process of solving problems by involving the members of the working group. When a working group is not able to break the chain of the problems caused by levels of difficulty outside the authority then the settlement problem shall be terrestrial in Decker in higher level management accordance with weights difficulty levels that appear.

Handling problems

Understand handling any problems always require field experience. By doing a series of exploratory questions are right on target, able to distinguish between the symptoms. The root of the problem, as well as a high objectivity. Why, because when problems are found then then it is often the first time out is not the root of the problem. But still the symptoms. The root of the problem could be at a different location, the time past or on other parts.

These conditions require a leader working group should be train in performing analysis using problem solving rules. Such as 7 steps (7 steps) solving problems with system Plan-Do-Check-Action (PDCA). Collectors the evidence, find things that are new approaches "5-Why" to identify. The root of the problem as the source of a problem becomes clear. Where at that time the thought of good will produce the best resolution. Very effective and structure, with low-cost but not low quality.

Effective analysis

The effective analysis is crucial to discover and understand the many potential causes of the problem. Of the many potential causes of this, we need to narrow down and produce attention on the most significant.

An environment that can give you the leeway on each person to be able to get use. To explore the problem at work. With its exploration of the issue incites other employees. To contribute ideas in settling the issue. Thus quality employees in problem solving be honed

  1. standards-based Process Control (Standard based Process Control)

The reference to the standardized job description of the referrer like (working instruction) should be understood and place on the strategic position at the operator's work area. Concern can also be use as a reference when the team leader and the responsible group leader. In order to process the checking of their validity during the audit of standardized jobs.

The implementation of actions in process control-base standards should be carry out through the audit process. Which is schedule directly regenerate, this is intend solely to maintain. To ensure the stability of implementation processes are consistent. Operators of the times have obtain deviate from standardize work. Because of a problem such as doing the work over and over. Standards-based control actions require identification and analysis that is the basis of doing to control the work to be consistent with the establish work process.

Audit Performance

There are two things that cause the need for the audit performed. The first was the discovery of a problem, what causes the onset of a problem. What caused the slowness of the process . Both may indeed it is time for audits to ensure the stability of the application of the work. Auditing allows the discovery of  from the standard method. The reason he did was to find the causes of the audit issues. That have an impact on the process and be the beginning of actions for improvement as a basis for improvements.

Standard procedure in an industry standard work process, covering the route of the flow of material in the factory. The production results, use papa color code, workplace hygiene, facilities and tools use. The placement of the material safely, identification material etc.

Any clues to the work of basically made rules in conducting the process of standardize workmanship. Though many circles that say that puts the work intend. To standardize the operator / concern employee can refer to him when doing the work assign.

Standard jobs & Descriptions

Reference to standard jobs, job descriptions, instructions for likes (working instructions) should be well understood. In a strategic position at the operator's work area. It is intended to be seen easily by the operator concern can also be use. As a reference when the team leader and the responsible group leader are in order to facilitate the process of checking the validity of the audit while doing standardized jobs.

The implementation of actions in process control-base standards should be carry out through. The audit process which is schedule directly regenerate. This is intended solely to maintain and ensure the stability of implementation processes are consistent.

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