Kamishibai

Definition

Kamishibai is a visual management system from Lean Manufacturing that supports structured audits, inspections, and continuous improvement processes through a card-based board. The term originates from Japanese meaning "paper theater" - a reference to the original use of picture cards for storytelling.

Functionality and Structure

The Kamishibai board consists of color-coded cards representing different audit or inspection topics. Green cards show completed inspections, red cards mark identified problems, and yellow cards signal ongoing activities.

Cards are systematically rotated to ensure all critical areas are regularly reviewed. Each card contains specific audit criteria, responsibilities, and time requirements for execution.

Modern Kamishibai systems integrate digital solutions with mobile apps for audit execution and automatic documentation of results.

Management Benefits

• Structured Leadership: Systematic Gemba walks and leadership rounds through all production areas
• Problem Visualization: Immediate visibility of deviations and improvement opportunities
• Continuity: Regular, structured review of critical processes and standards
• Employee Engagement: Active participation of teams in improvement processes
• Traceability: Documentation and trending of audit results over time

Applications

Production Management: Leaders use Kamishibai for structured production walks, systematically reviewing safety, quality, delivery, and cost. Each card focuses on specific KPIs or workstations.

Quality Assurance: Quality teams use Kamishibai boards for regular process audits and compliance with work standards. Critical quality parameters are continuously monitored through rotating card deployment.

Maintenance: Maintenance teams deploy Kamishibai for preventive inspections and TPM (Total Productive Maintenance) activities. Machine conditions and maintenance needs are visually tracked.

Workplace Safety: Safety officers use the system for regular safety inspections and compliance with occupational safety standards across different production areas.

Digital Kamishibai Implementation

Tablet-based Kamishibai applications enable digital audit execution with photo documentation and automatic data transmission. Digital dashboards visualize audit trends and identify recurring problem areas.

Integration with existing production monitoring systems allows automatic linking of audit results with production metrics and quality data.

Implementation Steps

Successful introduction begins with defining critical inspection areas and frequencies. Standardized audit checklists are developed for each card and responsibilities clearly assigned.

Training sensitizes leaders to systematic use and value of structured audits. Pilot areas demonstrate effectiveness before company-wide rollout.

Best Practices

• Regularity: Consistent execution according to defined rotation schedule
• Action Orientation: Immediate action definition for identified problems
• Visualization: Clear, understandable presentation of status and trends
• Escalation: Defined processes for critical findings and deadline overruns

Success Measurement

KPIs such as audit completion rate, problem resolution time, and trend development measure Kamishibai system effectiveness. Regular evaluation continuously optimizes inspection criteria and frequencies.

Kamishibai evolves into a central element of visual management that systematically advances leadership excellence and continuous improvement.