Eliminating Losses Through Makigami Analysis
MAKIGAMI ANALYSIS technique is a structured approach to detect all the losses that are occurring in the flow of an activity; be it a manufacturing process from the raw material purchase stage to the finished product dispatch stage or a cheque processing from the invoice receipt to the cheque dispatch or many more such cases. It captures all the sub activities of a process in depth; and analysis is done for identifying the non – value – adding activities or losses and action taken to solve them. The methodology adopted in this process would lead to the best design of a future state process based on loss elimination.
It is a simple but very effective tool that has given excellent benefits for those companies which have applied them to their processes of manufacturing or the administrative offices.
The Advantages of Makigami is:
- Structural Process Mapping Technique
Compared to Value Stream Mapping (VSM):
- Can tackle with non-visible flows
- Interfaces are identified easily
- Process is mapped in detail
- Losses are identified easily
- Faster Throughput time
- Less Transfers
- Less Output errors
- Decrease in Non-VAT or increase in job quality
The primary objective of the Makigami Analysis is to:
- Understand the existing process
- Identify as many sub processes as possible within the process
- Look for scope of improvement in each of the sub process
- Identify and take action on the losses to develop a highly efficient process
There are 7 steps to follow when you will work with Markigarmi
- Understand the process and start measuring performance
- Describe the process
- Restore basic conditions
- Define the current best standard
- Identify further opportunities for Process improvement
- Understand the anomalies of the new process and eliminate them
- Standard update and training
Below the steps in more details:
Understand the process and start measuring performance
1.1 Identify the process boundaries, interfaces and ownership
1.2 Identify customers and their requirements
1.3 Define process performance indicators
1.4 Set up a data collection system
Describe the process
2.1 Describe the process for each owner in detail.
2.2 Collect all necessary documents physically.
2.3 Connect all activities with communication lines.
Restore basic conditions
3.1 Process inspection and tagging
3.2 Calculate the Makigami-Indicators
3.3 Check basic conditions / standards and restore them
Define the current best standard
4.1 Transfer the value added activities.
4.2 Check if process is still working.
4.3 Analyze the problems and losses and find countermeasures.
4.4 Implement improvement actions and follow up anomalies.
4.5 Formalize the new standard.
4.6 Provide the necessary training.
Identify further opportunities for Process improvement
5.1 Apply the ECRS technique
5.2 Formalise the improvement ideas
5.3 Start the new standard
Understand the anomalies of the new process and eliminate them
6.1 Analyse the anomalies and find countermeasures (use your data collection system, e.g. our Loss Management Tool)
6.2 Follow up the results
Standard update and training
7.1 Update the standard
7.2 Provide the necessary training