Manufacturing shop floorr

Root Cause Analysis

When you find a problem, getting down to its true cause and addressing it at the root level are crucial to prevent the same issue from happening again. Akinori Hyodo explains how you can get down to the core of the issue and stresses the importance of taking this approach over and over when faced with a problem in order to increase the level of precision of your problem solving.

Visualizing Problems

Visualizing Problems

Following on from the previous #AskSensei webinar on the topic of visual management boards, we continue to discuss the importance of visualization and visualizing problems in your work place. Akinori Hyodo explains why this is important and draws some simple but effective examples from Japanese factory shop floors.

Visual management board example

Visual Management Boards

Visual management boards are a useful tool to have in your workplace. The tool allows you to grasp the necessary information at a glance and helps you to keep track of your operations against your set goals. However, if you have visual management boards in your workplace, are you using the tool correctly as it is truly intended? Akinori Hyodo discusses the idea of visual management boards and explains how you can best utilize this lean management tool.

Shinka Consultants on Shop Floor

How to Read a Factory

Having the ability to read and look at a factory or workplace properly is one of the important skills for those in a management position. How should you go about observing your site and what are the important points for you to pay attention to? Akinori Hyodo shares his thoughts on the thinking and approach on this important topic.

5s Seiso in Food Processing Plant

The Importance of 5S | The fourth S – Seiso (Shine)

The word seiso which is often referred to as shine in 5S literally means “cleaning” in Japanese. As the word suggests, one goes through the process of cleaning in the shine or seiso stage of 5S. But, Akinori Hyodo emphasizes the importance of establishing a standard around the level of shine that you are going to achieve and visualizing the information amongst your organization. Hyodo Sensei explains the reasons as he discusses the fourth S process of shine.

5S in Lean Factory

The Importance of 5S | The first S – Seiri (Sort)

In the world of lean, 5S is often considered as the basis for all improvement. When 5S is implemented thoroughly and continuously, it contributes to the elimination of waste and improvement of workplace efficiency as problems and issues are exposed and visualized much more easily. In this #AskSensei event we discuss the first S – seiri (sort).

Lean Factory Tour


Poka-yoke is a well-known Japanese term in the world of lean. It means “error-prevention” or “mistake-proofing” and the implementation of poka-yoke on the shop floor is regarded positively and encouraged in general. But, should this really be the case? Akinori Hyodo discusses the idea of poka-yoke and explains a potential pitfall around its implementation.