Hoshin Kanri: Policy Deployment for Successful TQM

245 Pages·2004·7.305 MB·English

by  Yoji Akao

HOSHIN KANRI
Yoji Akao
Author and Editor-in-Chief
Tamagawa University, Japan
Introduction by Greg Watson
Director of Corporate Quality,
Compaq Computer Corp.
Translated by Glenn H. Mazur
and Japan Business Consultants, Ltd.
Productivity Press
NEW YORK, NEW YORK
HOSHIN KANRI
Policy Deployment
for Successful TQM
PnMluctMlyJpress
CRC Press
Taylor & Francis Group
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Boca Raton, FL 33487-2742
© 2004 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group
No claim to original U.S. Government works
Printed in the United States of America on acid-free paper
15 14 13 12 11 10 9 8
International Standard Book Number-13: 978-1-56327-301-8 (Softcover)
Library of Congress catalog number: 2004009539
Cover design by Gary Raggaglia. Art creation by Lorraine Millard
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Contents
Tables and Figures ix
Publisher's Message xiii
Preface xvii
Contributors xix
Introduction by Greg Watson xxi
Chapter 1. TQM and Hoshin Kami 1
Hoshin Kami and Target Control 4
Target and Policy 5
Target Deployment 6
Means Deployment 8
Target Deployment and Means Deployment 8
Hoshin Kami and Control Items 10
Hoshin Kami and QC Circles 13
Chapter 2. Promotion of Hoshin Kami 15
Overall Control System 18
Hoshin Kami: Basic Concept 18
Hoshin Kami as a Part of TQM 18
Basic Promotion of Hoshin Kami 19
Chapter 3. Control Items for Hoshin Kami 65
The Role of Control Items in Hoshin Kami Systems 67
Definition of a Control Item 68
System of Control Items 68
Concept of Control Items 70
Advantages of Determining Control Items 72
The Origin of Control Items in Hoshin Kami 72
Target Deployment and Control Items 73
Operation Zelcoba 76
Coordinating the Target-Means and Control Items 78
Planned Policy, Coordination, Determination 78
Implementing the Policy 81
vi HOSHIN KANRI
Evaluating the Progress of Implementation 81
Deployment of the Target-Means and Control Items 82
Hoshin Kanri and the Seven New QC Tools 82
Method of Determining and Using the Control Items 87
Points of Caution for Determining Control Items 93
Using Control Items 94
The Concept of Control Levels 98
How to Determine Control Levels 98
Chapter 4. Hoshin Kauri with Daily Control,
Gross-functional Management, and Work Plans 103
Hoshin Kami and Daily Control 105
Hoshin Kami and Cross-functional Management 109
Cross-functional Policy and Departmental Policy 112
Hoshin Kami and Work Plans 115
Merging Hoshin Kami and the Work Plan 115
Chapter 5. Implementation of Hoshin Kami: Case Studies 121
Case Study 1: Hoshin Kami at Aisin-Takaoka 123
Management Strategy 123
Types of Policy and Definitions 124
Features of Annual Hoshin Kami 126
Planning the Annual Company Policy 129
Case Study 2: Hoshin Kami at Toppan Printing 134
Case Study 3: Hoshin Kami at Hokuriku Kogyo 136
Case Study 4: Hoshin Kami at Kobayashi Kosei 138
Planning the Annual Policy 138
Deployment of the Annual Policy 139
Evaluation of Policy Fulfillment 140
Chapter 6. Hoshin Kanri as a Part of TQM: A Roundtable Discussion 153
Introductory Remarks 155
Fundamental Issues 155
How to Determine Target Values and Means 158
How to Determine the Control Items 161
How to Effectively Use Control Items 162
Relationship of Hoshin Kanri to Daily Management 164
Relationship to Cross-functional Management 165
QC for Strategic Management 167
Importance of the QC Approach 168
Contents vii
Appendix 1. History of Hoshin Kauri 171
The Impetus to Systemize Hoshin Kami 171
Relationship between Hoshin Kami and Target Control 174
Relationship between Hoshin Kami and QC Circles 176
Appendix 2. Chronology of Hoshin Kami 179
Appendix 3. Management Strategies 185
The Era of Strategic Management 185
Bibliography 193
About the Author/Editor-in-Chief 210
Index 203
NOTE: Due to the format requirements of the illustrations, many of which are two-page
spreads, you will occasionally find a blank page. Please note that these are intentional,
and that there is no material missing from the book.

Tables and Figures
Figure 1-1. Control Point Setup Chart (Flag Method) 7
Figure 1-2. Target-Means Relationship Matrix Chart (Conceptual Chart) 9
Figure 1-3. Matrix Deployment 11
Figure 1-4. Implementation Plan and Its Administration 12
Table 1 -1. Control Item Terminology 13
Table 2-1. Definitions of Hoshin Kami 17
Figure 2-1. Overall Control System at Bridgestone Tire Company
(Awarded 1968) 19
Figure 2-2. Overall Control System at Komatsu (Awarded 1964) 20
Figure 2-3. Hoshin Kami: Basic Concept • 23
Figure 2-4. Hoshin Kami at Kobayashi Kosei 24
Table 2-2. Company Motto, Management Concept, and Quality Policy
(Simple Form) 25
Table 2-3. Environmental Changes Affecting Management Strategy (1) 27
Table 2-4. Environmental Changes Affecting Management Strategy (2) 27
Table 2-5. Collection and Analysis of Information 29
Table 2-6. Check-Act Study Chart 30
Figure 2-5. Results Analysis Sheet (Kobayashi Kosei) 31
Figure 2-6. Basic Information Summary (Kobayashi Kosei) 31
Figure 2-7. Setup (Flag Raising) and Deployment of Control Points
(Komatsu) 32
Figure 2-8. Target Deployment by Flag Method for Cost Reduction
(Komatsu) 35
Figure 2-9. Responsibility and Authority of Department Head and
Section Heads 36
Figure 2-10. Relationship among Requirements for Policy Planning 38
Figure 2-11. Department Action Plan (Hokuriku Kogyo) 42
Figure 2-12. List of Control Items (Hokuriku Kogyo) 43
Figure 2-13. Concept of Functional Control 45