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Kaizen Concept

Kaizen Concept

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5 s concept 5 s concept Presentation Transcript

  • 5STHE SECRET TOJAPANESE SUCCESS
  •  WHAT PROBLEMS DO U COMMONLYENCOUNTER AT YOUR WORKPLACE HIGH ABSENTEEISM HIGH TURNOVER DEMOTIVATED EMPLOYEES DISORDERED/ CLUTTEREDENVIRONMENT MISTAKES/ERRORS
  •  THE SOLUTION TO ALL THESEPROBLEMS IS5S
  • 5SHOUSEKEEPING TECHNIQUEPRODUCTIVITY AND SAFETYENHANCEMENT TECHNIQUE
  • IDEA BEHIND 5S IN ORDER TO ACHIEVE HIGHLEVELS OF QUALITY, SAFETY,ANDPRODUCTIVITY, WORKERS MUSTHAVE A CONDUCIVE WORKINGENVIRONMENT
  • WHAT IS 5S? Developed by the Japanese Housekeeping System Helps Create a Better WorkingEnvironment and a ConsistentlyHigh Quality Process
  • THE 5S PRINCIPLES SEIRI – Organisation/Sort out SEITON – Orderliness/Systemize SEISO – The Cleaning/Shining SEIKETSU – STANDARDIZE SHITSUKE - Sustain/Discipline
  • DISCOVERY OF 5S Thirty years ago researchers startedstudying the secret of success ofJapanese manufacturing companies 5S turned out to be the mostimpressive "secret" The factories were so well organizedthat abnormal situations were readilyapparent
  • DISCOVERY OF 5S Equipments were so clean and wellmaintained that any problem suchas a loose bolt or leaking oil couldbe easily seen This passion of cleanliness andorderliness became a hallmark ofJapanese organizations
  • ADVANTAGES OF 5S If tools and materials are convenientlylocated in uncluttered work areas Operators spend less time looking foritems This leads to higher workstationefficiency, a fundamental goal in massproduction
  • ADVANTAGES OF 5S A clean and tidy workplace leadsto greater well being and increasedmotivation Company image improves
  • ADVANTAGES OF 5S Health and Safety is ensured Machine maintenance Quality Productivity Lean Manufacturing
  • ADVANTAGES OF 5S RESULTS IN A PLACE EASIER TOMANAGE SMOOTH WORKING NOOBSTRUCTION NO DEVIATION, NO PROBLEMS B/C EVERYONE KNOWS WHERE THETHINGS ARE SPPOSEDF TO BE
  • ADVANTAGES OF 5S TIME SAVING QUICK RETRIEVAL ACCIDENTS & MISTAKESMINIMIZED INCREASES SPACE CREATES WORKPLACEOWNERSHIP
  • METHODOLOGYOF 5S
  • 1. ORGANISATION(SEIRI) Decide what you need Remove unnecessary clutter All tools, gauges, materials, classifiedand then stored Remove items which are broken,unusable or only occasionally used
  • RED TAG TECHNIQUE GIVE STAFF RED LABELS ASK STAFF TO GO THROUGHEVERY ITEM IN THE WORK PLACE ASK IF NEEDED & THOSE THATARE NEEDED,IN WHAT QUANTITY NOT NEEDED RED TAG IT STORE IN THE RED TAG AREAREDTAG
  • For wavering items PLACE THE SUSPECTED ITEMS INTHE RED TAG AREA FOR ONEWEEK ALLOW THE STAFF TOREEVALUATE THE NEEDED ITEMS AT THE END OF WEEK THOSEWHO NEED ITEMS SHOULD BERETURNEDREDTAG
  • ORGANISATIONPRIORITY FREQUENCY OF USE HOW TO USELow Less than once peryearOnce per yearThrow awayStore awayfrom theworkplaceAvg. Once per monthOnce per weekStore togetherbut offlineHigh Once Per Day Locate at theworkplace
  • 2. ORDERLINESS(SEITON) ONCE YOU HAVE ELIMINATED ALLTHE UNNEEDED ITEMS NOW TURN TO THE LEFT OVERITEMS
  • ORDERLINESS(SEITON)Organise layout of tools andequipment–Designated locations–Use tapes and labels–Ensure everything isavailable as it is needed andat the “point of use”
  • ORDERLINESS(SEITON)Workplace Checkpoints:- Positions of aisles and storage placesclearly marked? Tools classified and stored by frequencyof use? Pallets stacked correctly? Safety equipment easily accessible? Floors in good condition?
  • 3. SEISO (CLEAN/SHINE) Create a spotless workplace Identify and eliminate causes ofdirt and grime – remove the needto clean Sweep, dust, polish and paint
  • SEISO (CLEAN/SHINE) Divide areas into zones Define responsibilities for cleaning Tools and equipment must be owned byan individual Focus on removing the need to clean
  • 4. SEIKETSU (STANDARDISE) Generate a maintenance system for thefirst three Develop procedures, schedules,practices Continue to assess the use and disposalof items Regularly audit using checklists andmeasures of housekeeping Real challenge is to keep it clean
  • 5. SHITSUKE (SUSTAIN / DISCIPLINE) Means inoculate courtesy & good habits Driving force behind all 5S Make it a way of life Part of health and safety Involve the whole workforce* Develop and keep good habits
  • LITMUS TEST FOR 5S 30 SECOND RULE ONE MUST LOCATE THE ITEM WITHIN 30 SECOND IF 5S IS PROPERLYIMPLEMENTED
  • WHAT U HAVE COME ACROSSAT THE END OF DAYFollowings can be harnessed form the5S1. NEAT & CLEAN WORKPLACE2. SMOOTH WORKING3. NO OBSTRUCTION4. SAFETY INCREASES5. PRODUCTIVITY IMPROVES
  • Cont.6. QUALITY IMPROVES7. WASTAGE DECREASE8. MACHINE MAINTENANCE9. VISUAL CONTROL SYSTEM10. EMPLOYEES MOTIVATED11. WORKSTATIONS BECOMESPACIOUS
  • Before 5S
  • After 5S
  • After 5S
  • After 5S