KAIZEN

1. KAIZEN KAIZEN Is a Japanese word which means… • Change for better. • quest for continuous improvement.

2. TOOLS / METHOD TO MAKE KAIZEN WORK: • 1. Human Resources(HR) emphasis • 2. Three(3) balloons to success • 3. Three(3) M for doing a job. • 4. Five(5) S strategy • 5. Five (5) fields of training • 6. Seven(7) types of waste • 7. KAIZEN continuous improvement board. IMPORTANT: “ EVERYONE SHOULD BE RESPONSIBLE AND EVERYBODY SHOULD PARTICIPATE TO ACHIEVE KAIZEN” …especially the TOP management.

3. 1. Human Resources(HR) emphasis

4. 2. Three(3) balloons to success

5. 3. Three(3) M for doing a job.

6. 4. Five(5) S strategy

7. 5. Five (5) fields of training

8. 6. Seven(7) types of waste

9. 7. KAIZEN continuous improvement board.

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 organization • It is a concerted company-wide or organization-wide effort to maintain the workplace clean, orderlyandwell-organized.

13. What is 5S? 5Sis a systematized approach to: • organize work areas • keep rules and standards • maintain discipline 5Sutilizes: • workplace organization • work simplification techniques 5S practice: • develops positive attitude among workers • cultivates an environment of efficiency, effectiveness and economy

14. 3rd Rate WorkplacePeople leave trash, …no one picks it up.

15. 2nd Rate WorkplacePeople leave trash, …but others pick it up.

16. 1st Rate WorkplaceNo 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 the • company’s business but also to the people who practice it. • 5S makes your workplace more pleasant • 5S makes you work more efficiently • 5S 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 symptoms • Participation of everybody is required

22. 5Sdefined… Action Identifying and eliminating all unnecessary items. Arranging necessary items in good 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. Original Japanese Seiri Seiton Seiso Seiketsu Shitsuke Meaning in English Sort Systematize/ Set Sweep/Shine Sanitize/ Standardize Sustain/ Self-Discipline 5S 1S 2S 3S 4S 5S

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 item is 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 needed or not. - If no one needs the item after 3 months, it only means that the item is no longer needed hence, dispose the item 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 eliminated from 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 even people passing your desk from this point of view to ensure safe and efficient operation. Step 2: - Place frequently needed items close to the user to minimize effort and time wastage. - Things that are not used often could be places slightly farther away. - Make a plan on these principles and locate/store things accordingly.

28. Placement of Materials/Equipment Based on Frequency of Use Priority Frequency of Use How to Store Low Less than once a year Throw away Once a year or so Store in distant place Average Once every 2-6 months Once a month Store together some- Once a week where in the office High Once a day Carry or keep at Once an hour your workplace

29. STEP 3: - It is necessary to make sure that everyone in your workplace knows where things are kept for efficient • use. • - Make a list of things with their locations. • - Label each drawer and cabinet to show what is • kept inside. • STEP 4: - Apply the same principles as in Step 3. • - Indicate the places where fire extinguishers are • located as well as passages for carts. • - Place warning signs for safety precautions. • NOTE: • Three Rules for Storage Space • Get rid of all unnecessary items • Decide proper storage layout/classification • Standardize names

30. Arrange necessary items in good order • prevent loss and waste of time • easy to find and pick up necessary items • ensure first-come-first-served basis • make production flow smooth and work easy

31. SEITON PRACTICES • Don’t place goods in frontage along passages • Store goods for first-in-first-out retrieval • Everything must have its location • Label items and their location systematically, mark everything • Separate special tools from common ones • Frequently used items nearer to the user • Make things visible to reduce searching time, organize by color • Keep space for safety equipment and evacuation passages clear

32. Things used constantly Place as close as possible Things needed Things used occasionally Place a little further away Seldom used, but still needed Enclose in a separate, designated place Classification No potential use Immediate disposal Things not needed Potentially useful or valuable Consider where useful and move Requiring special disposal Arrange responsible, inexpensive disposal

33. 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 equipment Clean 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 going home (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 products • prevent deterioration of machinery and equipment and make checking of abnormalities easy • keep workplace safe and work easy

37. SEISO PRACTICES • Big Seiso ( Clean-Up Day ) • 3-5 minute cleaning daily • Assign owner to each machine • Combine cleaning with inspection • Make daily maintenance points clear by providing visible instructions • Prevent 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 compliance with 3S. - Remember the 3 “NO” principles:  No unnecessary items  No mess  No dirt Step 2: - Make a schedule for cleaning your workplace. Step 3: - Interdepartmental competition and cooperation is a very effective means of sustaining and enhancing people’s interest in 5S

40. SHITSUKE (SUSTAIN/SELF-DISICPLINE) • PROCESS/PROCEDURE: • Step 1: - Create reasonable rules. •  Create reasonable rules of behavior in the • workplace. Engage everyone concerned in the • creation of rules not just the department heads or • supervisors. •  Discuss the rules with everyone concerned. This • will result to a feeling of involvement. •  Show rules and standards clearly and attractively • using illustrations, photographs and color-coding. • Step 2: - Exhibit before and after 5S photos where everyone • will 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 orderliness • Prevent misoperation • Make it easy to find out abnormality • Standardize good practices

42. SEIKETSU PRACTICES • Visual control signs • Color coding • Maintenance labels • Fixed-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. Safety Helmet Head Lamp SELF-DISCIPLINE (SHITSUKE) Clean Uniform Train people to follow good housekeeping rules autonomously.

45. (SHITSUKE…) • Enhance autonomous management activities • Maintain the discipline needed to do a good job • Upgrade productivity and quality consciousness

46. SHITSUKE PRACTICES • Wash hands after going to the toilet • Wash hands before and after meals • Eat and smoke at designated places • Keep workplace always clean and tidy • Wear clean uniform and shoes • Follow safety rules • Put things back in their proper places • Work according to standards • Observe proper office decorum

47. BENEFITS OF 5S • A clean and organized workplace ..…. • High in PRODUCTIVITY • Produces QUALITY products and services • Reduces COST to a minimum • Ensures DELIVERY on time • SAFE for people to work in • Makes employee MORALE high

48. 5S in WORK STATIONS • VISIBLE RESULTS: • Decrease in the number of accidents and close calls • Proper storage • Improved productivity • Greater people involvement in improvement activities • Better use of floor space • Early detection of problems • High product quality • Decreases delay • Low employee turnover • Low machine breakdown rates • Detection system • Zero breakdown • INVISIBLE RESULTS: • Happier employees with high morale. • Happier customers.

49. “GOOD, BETTER, BEST NEVER LET IT REST TILL THE GOOD IS BETTER AND THE BETTER IS BEST”

50. Thank You! Yekenelle!