Presentation on theme: "KAIZEN KAIZEN Is a Japanese word which means… Change for better."— Presentation transcript:
1 KAIZEN KAIZEN Is a Japanese word which means… Change for better. quest for continuous improvement.
2 1. Human Resources(HR) emphasis 2. Three(3) balloons to success TOOLS / METHOD TO MAKE KAIZEN WORK:1. Human Resources(HR) emphasis2. Three(3) balloons to success3. Three(3) M for doing a job.4. Five(5) S strategy5. Five (5) fields of training6. Seven(7) types of waste7. KAIZEN continuous improvement board.IMPORTANT:“ EVERYONE SHOULD BE RESPONSIBLE AND EVERYBODY SHOULD PARTICIPATE TO ACHIEVE KAIZEN” …especially the TOP management.
10 Among the seven(7) tools/methods to achieve kaizen, … it is the 5S that is most applicable to our everyday work and life.Thus we employ to utilize this strategy,and apply in our everyday life and work to achieve kaizen.
11 5S – A Housekeeping Techniques and Strategy CONCEPTS AND PRINCIPLES:1. SEIRE (Sort)2. SEITON (Systematize / Stabilize / Straighten)3. SEISO (Sweep / Shine)4. SEIKETSU (Sanitize / Standardize)5. SHITSUKE (Self-discipline / Sustain)
12 What is 5S?5S means good housekeeping and workplace organizationIt is a concerted company-wide or organization-wide effort to maintain the workplace clean, orderly and well-organized.
13 What is 5S? 5S is a systematized approach to: 5S utilizes: organize work areaskeep rules and standardsmaintain discipline5S utilizes:workplace organizationwork simplification techniques5S practice:develops positive attitude among workerscultivates an environment of efficiency, effectiveness and economy
14 3rd Rate Workplace People leave trash, …no one picks it up.
15 2nd Rate Workplace People leave trash, …but others pick it up.
16 1st Rate Workplace No one leave trash, …but people would pick it up if they see it.
18 What can you gain from 5S?Practicing 5S brings benefit not only to thecompany’s business but also to the people who practice it.5S makes your workplace more pleasant5S makes you work more efficiently5S improves your safety
19 What can a company gain from 5S? P 5S increases PRODUCTIVITY.Q 5S improves QUALITY.C 5S reduces COST.D 5S makes DELIVERY on time.S 5S improves SAFETY.M 5S improves MORALE.
20 Why 5S brings such benefits? 5S improves CREATIVITY of people.5S improves COMMUNICATION among people.5S improves HUMAN RELATIONS among people.5S improves TEAMWORK among people.5S improves CAMARADERIE among people.5S gives VITALITY to people.
21 5S PHILOSOPHY Productivity comes from the elimination of waste It is necessary to attack the root cause of a problem, not just the symptomsParticipation of everybody is required
22 Action Original Japanese Seiri Seiton Seiso Seiketsu Shitsuke 5S defined…ActionIdentifying and eliminating all unnecessary items.Arranging necessary items ingood order and easy access.Cleaning workplace thoroughly.Maintaining high standards of housekeeping and workplace organization at all times.Creating a culture wherein all members practice the above 4S as a way of life.OriginalJapaneseSeiriSeitonSeisoSeiketsuShitsukeMeaning in EnglishSortSystematize/SetSweep/ShineSanitize/StandardizeSustain/Self-Discipline5S1S2S3S4S
23 1. SEIRE (SORT)Sorting is a step that involves selecting what you need to complete the job and removing everything else from your work area.Taking out and disposing unnecessary items.Sort/classify the items that you “need” from the items that you “want or not needed”.Dispose the items that you do not need and regroup the items that you need..Clearly distinguish needed (frequently used) items from unneeded items and eliminate the later.
24 SEIRI (SORT) PROCESS/PROCEDURE: Step 1: - Look around your workplace with your colleagues.- Decide and identify which items are unnecessary for you.- Dispose of unnecessary items.Step 2: - If you and your colleagues cannot decide if an itemis unnecessary, place a Disposal Notice on the item,indicate the date and set the item aside.Step 3: - After a certain period, check if the item is still neededor not.- If no one needs the item after 3 months, it only meansthat the item is no longer needed hence, dispose theitem right away.
25 NOTE:It is recommended that this approach be used company-wide, involving people from different departments.Never keep anything which is unnecessary to your work.While looking around for unnecessary items in your workplace, look at every nook and corner like when you are looking for cockroaches.
26 2. SEITON (SYSTEMATIZE / SET IN ORDER / STRAIGHTEN). This step customizes your workstation and surrounding area to meet your work area needs. Arrange remaining items so they are easy to select, use, and to return to their proper location.Arrangement / organization of necessary items in good order for use.Keep needed items in correct place and sequence of use to allow easy and quick retrieval.
27 SEITON (SYSTEMATIZE/SET) PROCESS/PROCEDURE:Step 1: - Make sure that all unnecessary items are eliminatedfrom your workplace.- Decide where you can place necessary items.- Take into consideration the flow of your work.- Take into account the movement of carts or evenpeople passing your desk from this point of view toensure safe and efficient operation.Step 2: - Place frequently needed items close to the user tominimize effort and time wastage.- Things that are not used often could be placesslightly farther away.- Make a plan on these principles and locate/storethings accordingly.
28 Placement of Materials/Equipment Based on Frequency of UsePriority Frequency of Use How to StoreLow Less than once a year Throw awayOnce a year or so Store in distant placeAverage Once every 2-6 monthsOnce a month Store together some-Once a week where in the officeHigh Once a day Carry or keep atOnce an hour your workplace
29 STEP 3: - It is necessary to make sure that everyone in your STEP 3: - It is necessary to make sure that everyone in your workplace knows where things are kept for efficientuse.- Make a list of things with their locations.- Label each drawer and cabinet to show what iskept inside.STEP 4: - Apply the same principles as in Step 3.- Indicate the places where fire extinguishers arelocated as well as passages for carts.- Place warning signs for safety precautions.NOTE:Three Rules for Storage SpaceGet rid of all unnecessary itemsDecide proper storage layout/classificationStandardize names
30 Arrange necessary items in good order prevent loss and waste of timeeasy to find and pick up necessary itemsensure first-come-first-served basismake production flow smooth and work easy
31 SEITON PRACTICESDon’t place goods in frontage along passagesStore goods for first-in-first-out retrievalEverything must have its locationLabel items and their location systematically, mark everythingSeparate special tools from common onesFrequently used items nearer to the userMake things visible to reduce searching time, organize by colorKeep space for safety equipment and evacuation passages clear
32 ClassificationThingsnotneededNo potential useThings used constantlyPotentially usefulor valuableThings used occasionallyRequiring special disposalSeldom used,but still neededPlace as closeas possiblePlace a littlefurther awayImmediate disposalConsider whereuseful and moveEnclose in a separate,designated placeArrange responsible,inexpensive disposal
33 Clean it so that defects are so easy to spot and eliminate. 3. SEISO (SHINE / SWEEP).This step is powerful because its purpose is to find the reason why things become dirty. Emphasis is on the removal of dust, dirt and grime to reveal the source and eliminate it.Cleaning of the workplace, including tools and equipmentClean it so that defects are so easy to spot and eliminate.
34 SEISO (SWEEP/SHINE) PROCESS/PROCEDURE: Step 1: - Determine the subject of clean up (what to clean)e.g., location (storage, shelves, etc.), equipment,space (passageway, room, etc.)Step 2: - Assign persons responsible for clean up (who, where).Step 3: - Determine the method of clean up (how to do it).- Target the ff areas for cleaning (storage,equipment and surroundings)- Draw up a cleaning responsibility map- Create a cleaning schedule.Step 4: - Implement cleaning.Step 5: - Make a daily 5-minute cleaning habit before goinghome (Keep it simple and easy to understand.)
35 NOTE:Do not wait until things get dirty.Clean your workplace; machines and equipment, tools and furniture regularly.Put aside 3-minute of seiso per day.Be responsible for your own work area.Never throw anything and make it your habit.Cleaning is also checking.
36 Clean your workplace completely keep environmental condition as clean as the level necessary for the productsprevent deterioration of machinery and equipment and make checking of abnormalities easykeep workplace safe and work easy
37 SEISO PRACTICESBig Seiso ( Clean-Up Day )3-5 minute cleaning dailyAssign owner to each machineCombine cleaning with inspectionMake daily maintenance points clear by providing visible instructionsPrevent causes of dust and dirt
38 4. SEIKETSU (SANITIZE / STANDARDIZE). This step creates a work area free of checklists; if good standards are put in place it will be easier to maintain and continue improving.Maintaining the workplace in high standard of housekeeping and organization.Set easy-to-follow standards and develop a structure to support the three first (S’s) pillars.
39 SEIKETSU (SANITIZE/STANDARDIZE) PROCESS/PROCEDURE:Step 1: - Establish standards for maintaining compliancewith 3S.- Remember the 3 “NO” principles: No unnecessary items No mess No dirtStep 2: - Make a schedule for cleaning your workplace.Step 3: - Interdepartmental competition and cooperation is avery effective means of sustaining and enhancingpeople’s interest in 5S
40 SHITSUKE (SUSTAIN/SELF-DISICPLINE) PROCESS/PROCEDURE:Step 1: - Create reasonable rules. Create reasonable rules of behavior in theworkplace. Engage everyone concerned in thecreation of rules not just the department heads orsupervisors. Discuss the rules with everyone concerned. Thiswill result to a feeling of involvement. Show rules and standards clearly and attractivelyusing illustrations, photographs and color-coding.Step 2: - Exhibit before and after 5S photos where everyonewill see them.Step 3: - Recognize good practices and good performance.
41 Maintain a high standard of housekeeping and workplace organization at all times. Maintain cleanliness and orderlinessPrevent misoperationMake it easy to find out abnormalityStandardize good practices
42 SEIKETSU PRACTICESVisual control signsColor codingMaintenance labelsFixed-point photography
43 5. SHITSUKE (SELF-DISCIPLINE / SUSTAIN). Sustaining is the end result of how well we have performed the previous four S’s. In the sustainability stage, think of ways to eliminate effort in maintaining an area.Doing things spontaneously without being told.Educate people so that 5S expands beyond initial limits and turns into natural standard behavior.
44 SELF-DISCIPLINE (SHITSUKE) Safety HelmetHead LampClean UniformSELF-DISCIPLINE(SHITSUKE)Train people to follow good housekeeping rules autonomously.
45 (SHITSUKE…) Enhance autonomous management activities Maintain the discipline needed to do a good jobUpgrade productivity and quality consciousness
46 SHITSUKE PRACTICESWash hands after going to the toiletWash hands before and after mealsEat and smoke at designated placesKeep workplace always clean and tidyWear clean uniform and shoesFollow safety rulesPut things back in their proper placesWork according to standardsObserve proper office decorum
47 BENEFITS OF 5SA clean and organized workplace ..….High in PRODUCTIVITYProduces QUALITY products and servicesReduces COST to a minimumEnsures DELIVERY on timeSAFE for people to work inMakes employee MORALE high
48 5S in WORK STATIONS VISIBLE RESULTS: Decrease in the number of accidents and close callsProper storageImproved productivityGreater people involvement in improvement activitiesBetter use of floor spaceEarly detection of problemsHigh product qualityDecreases delayLow employee turnoverLow machine breakdown ratesDetection systemZero breakdownINVISIBLE RESULTS:Happier employees with high morale.Happier customers.
49 “GOOD, BETTER, BESTNEVER LET IT RESTTILL THE GOOD IS BETTERAND THE BETTER IS BEST”