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Kaizen implementation in the Woreda level by the Woreda Kaizen team and TVET level

Kaizen implementation in the Woreda level by the Woreda Kaizen team and TVET level

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  • 1. Implementation of Kaizen in the enterprises by Woreda level industrial extension workers Document exploration in Woreda 3 Introduction Over all activity and implementation of Kaizen training by keeping the procedure in the particular of Kaizen implementation presented as follows 1. DETME enterprise where found in Gulela Sub-City Woreda 3 proximity to the health canter 2. DOBA/ATW enterprise >> >> >>> >>> >>>> Implementation of ‘Kaizen philosophy conducted in the two enterprises which founded in Gulele Sub-city at woreda – 3 leavel namely Lalibela Construction P.L.C. and Ralcon construction P.L.C. The full implementation package of Kaizen programme has been performed by the collaboration with woreda and TVET college Kaizen team on the enterprises. The name of enterprise is I. Lalibela Construction P.L.C Kaizen team which undertakes the full implementation package Participants (implementers) namely had undertaken the continual support for the sustainability of the implementation. II. Ralcon construction P.L.C, The Kaizen team which undertake the full implementation package namely; 1. Kaizen (scale productivity) 2. Identification of knowledge gaps and registration of those gaps 3. Assisting the concept of technology transfer 4. Job creation and market sharing among them. The reports of the above enterprises include detailed job description and throughout the work, the strength and weakness are analyzed by doing SWOT analyses.
  • 2. General Work Description of Kaizen implementation Starting from 16/04/04 E.C, inauguration of the enterprises, the implementation of Kaizen philosophy was introduced but the presence of holiday rendered the framework. After assessing their willingness, by forming a team (a group), we undergoes assessment on their willingness, finally we started the job. Detailed Work Description Shop layout, According to the shop layout, categorizing and labeling of equipments were done, new job store constructed. Arrangement done on raw materials, the class dividing was made by table was demolished, Appropriate shelves and tables were assembled on their proper place, Allocation of raw materials were done on the shelves both in / arrangement type and amount Transferring the arranged raw materials in tool store Cleaning the machines by benzene & compresses, Problem identification of malfunctioning machines, cleaning the room Appropriate disposal of the waste and waste storage on the boxes were done, Tools arrangements, Kaizen board was done, Waste storage box was done, Skill gap/need assessment time frame was done on the same date, Typing the arranged tools on compute, Posting them on the billboard, Purchasing of conduit breaker Training was given for accounting leather and the debt-credit capital was not registered properly on the capital statement, but the registration process of cash flow statement is done based on the daily basis. In addition, detail description, receipt no, cash, bank deposited, credit from shareholders, raw material, registration fee from shareholders, fixed equipments, payable credit, registration fee from new members, contingent deposit from shareholders, payable profit, telephone & electric power bill (expense), stationery expenses, transportation expenses, salary expense and other expenses were debited and credited. In lalibela construction, the files model were compiled, other files which are properly handled are: Personal profile of worker, Minute profile, Tender letter profile, we recommended them to create a file of another box file models and purchase order form. Work Description in Radical Construction
  • 3. Arrangement of storage for machine and raw materials, Temporary shop layout drawing preparation (preparation of temporary shop layout drawing), The metals and woods founded in the shop were deposited outside of workshop for proper implementation of the work plan Cleaning of workshops, Proper storage of raw materials, Proper assembly of machines based on shop layout, Assembling two benches in the workshop, Proper storage of raw materials for metal and wood work, Storing raw materials on their own appropriate place, Entry of shelves, Proper identification of raw materials and put them on shelves, Expiry metal & woods were properly disposed, Workshops, raw material storage, kaizen board, assembly room for machines, MDFC, Direction indicators were prepared by compressor and posted - Purchasing of conduit breaker, Electrical installation, Skill gaps were identified. These are: 1. Accounting 2. Metal work 3. Wood work 4. Management & leadership 5. Bookkeeping Ralcon Construction Cabinet for entry letters, Purchasing order folder, Workers private profile folder, Minute folder, Tender letter profile The problem identified in both enterprises is that proper cleaning of working environment after day-offs; lack of proper labelling of raw materials and produced goods; but by working together the problem was solved. Electrical installation on ground was done. Lastly additional box files purchasing proper utilization of them were recommended for them. Benefits Encountered Getting labeled goods within short period of time, proper cleaning of working environment Missed materials and goods are easily accessible, current good manufacturing practice created, time saved, Electrical installation that minimizes danger and working friendly Proper labeling of raw materials and work goods on shelves in stores, Proper identification and assembly of waste disposal, Expenses for purchasing of goods include:- Sanitary items, Electrical items like conduit and breaker Training need assessment tools were our questionnaire/interview
  • 4. Purchasing of steel products & selling of wastes as of Kaizen implementation, First aid kits were prepared for both enterprises, Business plan was prepared for both enterprises which include:- Business transaction and expenses, Monthly work plan, Monthly operational/cost plan/ material cost prepared, Cash flow plan was prepared Strength and Weakness of Kaizen Implementation 1.1. Strength Inauguration of industry extension in woredas, Active participation of workers and teachers of woreda industry extension services, Proper implementation of Kaizen by forming cluster centre among human resources, Forming team work and proper workflow among teachers in woreda and TVET colleges, The work plan is specific, measurable, achievable, reliable and time bound and it is effective 1.2. Weakness Lack of safety precaution clothes, No budget for medication purpose, Accidents due to lack of safety precautions, Lack of place for treating staffs, Lack of technology, equipments and materials, Non-inclusiveness of professionals in industrial extensions, Presence of implementation gaps due to long organizational structure, Lack of market opportunity, Need of total dependency, Lack of participation of cluster centre Limitation, Lack of willingness during implementation as of seven other enterprises did. Plan implementation gaps, Lack of safety precaution clothes, Lack of continues training and communication gaps between trainers with TVET teachers Possible Problem solving strategy Undertaking ideas for enterprises about Kaizen implementation, Fulfilling all the materials and equipments needed by discussing the issue with respective and responsible stakeholders Solving skill gap and identifying issues to be solved through long term & continuous training, Recommending the enterprises to implement the workflow process and the training given Solving or reducing knowledge, attitude and skill gaps through continuous training Creating effective professional goal to be achieved, Issuing the nearby health institutions to render better health far and treatment for them beyond rendering first aid. Summary
  • 5. Assets to be implemented for boosting productivity efficiency starting from 16/04/04 – 03/05/04 E.C are:- Sort – identification of raw materials for production and service, Stabilize – labelling and storing beneficial assets, Shining – cleaning of workshop & equipments and materials, Standardize – assuring quality for workshops, Sustain – keeping for continuity of Kaizen philosophy In addition Kaizen (increasing production & productivity efficiency), Identification and registration of skill gaps, Assisting them for technological transfer, Entrepreneurship & market opportunity creation Other tasks include space management & keeping modern production flow project outputs and impact is also their focus and the project all in all was SMART. Even though the service of industrial extension the city administration of A.A particularly in each sub-city and vocational school is started soon; many achievements have been observed. Among such success full accomplishments Kaizen system takes the lion’s share. This system helps this model in association with micro business activity. In addition with this industrial extension gives to those micro-business associations’ short term training to improve their skill business planning and financial management. This service has been implemented in each Woreda and sub-city .Due to this each micro business enterprise has got good progress in their activity. Beside this, the industrial extension gives short term training for an employee and females and enables them to have their job. In this respect Gullele sub-city Woreda 3 have done a good job which can be considered as a model for other sub-cities. The administration creates close contact with Vocational Schools to bring more trainers to be trained and finally enable them to start their Micro Business services. Moreover, they also create contact with different NGO’s or Charity Organizations to create good job opportunities for the trainees. Generally, the management has made good progress in this year than before. The overall activities of that industrial extension can be stated as follows:  A new machinery is donated to the newly emerged enterprises, and  The administration enables them to buy a new machine and begin their service that is three Micro Finance enterprises each having 20 members has bought a machine with
  • 6. 25,000,000 Eth birr. The coast doesn’t include the saving account which is given to them by saving and credit association of Addis Ababa. Activities Performed Through Kaizen The first and second round activities have been implemented for DTAM and Ras Emiru through Kaizen Systems. We did it basically with their own ------------.Now we are following their activities and still the following activities has been performed: Shop layout Preparation of materials according to shop lay out, a decision was made on having a new tool store have been implemented. Furthermore, the implementation of Kaizen continued Re-arrangement of raw materials, Room partition. Arrangement of Chair, table and Shelf, Arranging raw materials in accordance with quantity and Seat arranged raw material in tool store, Cleaning materials with comprador and Dicdel, Identifying problems of dysfunctional materials, Room cleaning, Kaizen board, Trashcan(Garbage), Stick quotations in timber, Training in auditing. Benefits of Kaizen The process of finding material takes 10-15 minutes before arrangement, but after implementation we were reducing 15 mints per single item materials hidden and poor ------- cleaning  Hidden materials found, creates conducive environment and time will be saved.  Problem of installation will be solved.  After installation conducive, visible safe environment will be created.  The ware house re-arranged and all materials situated In a clear visible area.  Garbage prepared and situated in a specified area. Expenditure for purchasing materials  Broom  Electrical materials such as Conduct breaker
  • 7.  Half kilo 5cm and 8cm nail purchased. The income was high after Kaizen implemented because pieces of metal scrap sold.  Filling the gap by giving training such as filling, auditing management.  Sanitation undertake, first aid box a bounded plan pre pared. such plans are:  Outcome which is planned monthly  Selling plan  Cash flow plan  Support given for those who need help Concerning the enterprises implemented Kaizen continues follow-up support Among the works in this year visiting, observing and assessing enterprises and associations which implemented Kaizen such as Lalibella, Raccon, DETEMA wood and metal enterprise. Accordingly: 1. Lalibella Wood and Metal Enterprise Strangth: Place of the machine, organized office, cleanliness, their work flow is work centered Drawback: hand tool raw materials, Kaizen boards are twisted, misplaced in un proper lace Support: Give help, advice in order to arrange sitting materials in proper way. 2. Rlaccon Wood and metal enterprise Strength: cleanliness the environs Drawback: Manufacturing wood and metals products together misusing flow of work (is not work centered), no Kaizen board, unwillingness of accepting expertise advice and support. Support: give advice to --------working rooms, give expertise support such as cleanliness of work place. 3. DTM wood and meals Enterprise Strength: Organization using the office is better, Work flow and cleanliness of shade. Drawback: Misuse of raw materials and improper placing of hand tools.
  • 8. Support: give advice for placing raw materials and hand tool Regarding of the training Industry extension within 6 month of Kaizen implementation, short term training of women and unemployed in entrepreneurship conducted with the cooperation of TVETs in the first, second and third round. After training conducted the trainees were organized in association and start operation .Trainees are: In terms of first round training: The aim was to train 500 unemployed trainees, but 402 of them were trained in different fields in Entoto and Shro Meda Technical and Vocational College with related to job creation and business plan. The coordinators work leaders got private plan beside 1 to 5 plans and a check list. Additionally time is allocated for meetings to assess---------.During second round there was no attitude gap in institution level because problems identified and solved in the first round training. Training is conducted deliberately and trainees working privately, in factories and also in associations. Kaizen Workshop management, business plan, work ethics, leadership, recourse management --- ---plan preparations credit and service, book keeping, market competency ,trainings given by Vocational schools. The training conducted for SMEs by the Kaizen team in two rounds. The first training conducted in the first two days but the second round was wider and it takes 1 week. The training was vital to fill the gap. Regarding the input more or less there had been no shortage excluding Computer and table. A ground plus 4 building is underway by world Vision .The operation was lagging behind due to absence of Engineer, but now the contractor hired engineers and the building process is taking place on a large scale. In addition to this the charity organization is willing to help organized trainees. Namely: 1. Unity Blocket Enterprise Private Limited Company with 15 members. 2. Yenege tesfa Blocket Enterprise Private Limited Company with 23members.
  • 9. 3. Entoto Blocket Private Limited Company with 20 members. 4. Jantekel Blocket Private Limited Company with 20 members. And the total number of these associations is 78.After they organized themselves in associations they requested to be aided by the following materials; Blocket production machine, Plastic pipe, Spade, Spoon for concrete mixing, Glove, Wok uniform This was presented for the charity organization with specification and they are waiting for the purchase and delivery of the materials to begin their work. In Shro Meda Training institution all the materials were purchased by World Vision. For all departments machineries and accessories were purchased and the remaining is on process, specifically for leather department many types of machinery were bought, but machineries for shoe manufacture are not still purchased. Woreda 3 Report on the Implementation of Kaizen Introduction: Kaizen is being implemented in behind health centres found around woreda 3 near Menen preparatory school the report was prepared by woreda 3 industrial extension servants found working in woreda 2 & 3. This activity is aided by Industrial extensions for small scale enterprises modulated by Entoto cluster. This is done in accordance with the growth and transformation plan of the country or its implementation plays a vital basis for the economic growth. This is through well equipped manpower technological transfer that is in accordance with the market situation of small scale enterprises and focus on productivity, quality based products. The industrial extension implementation of 1st round Kaizen in our woreda starts from Nov /10/2005 E.C – 29/03/2005 E.C. This was modulating with Entoto TVET College for 2 enterprises. These are: 1. Ediget behibret dry food manufacturers PLC 2. Beza wood & metal work enterprises The enterprises starts with 5 shareholders with initial capital of 15,000 from shareholders, nowadays the shareholders are 11 and 5 full time workers with a total of 16 workers. Problems encountered while implementation Attitudinal problem, Proper utilization of working time, Limitation of planning, Limitation of fulfilling some input materials
  • 10. Skill gap, Communication / unity problem , Shortages of professionals in all discipline Input , Lack of important inputs for the enterprise as a result quality problem, Lack of Amharic version training materials, Improper utilization time, Safety materials shortage, Thines of attendance of trainee, Lack of trainers (teachers) due to burden of work Problem of the Enterprise Attitudinal problems, Absolute dependency, Problem of work flow, Problem of time utilization Skill, Gap of commercial planning, commercial leadership and material handling problem, Bookkeeping and accounting problem, Machine operation and safety problem Input, Lack of standardized machineries & lack of prevention tools, Lack of safety tools, Sanitation problem, Problem solved from the enterprises Attitudinal problem, By creating attitudinal & awareness change, dependency tied to be solved. Input problems solved and material cost paid by enterprises, The training was as much as possible inclusive of all stakeholders, Promoting continuous work flow system Filling skill gap, Creating awareness on credit, Govern training on commercial leadership and machine operation, Practices on inputs (implementation activities on input), Recommendation has been given on the work flow process, As far as safety clothes were concerned, uniform should be used by individuals, Procurement of materials that are not available in the shop (ordered to purchase shortcoming materials) Results Productivity Improvement, Arranged the working place and disordered materials and recommended to work in accordance with proper work flow process, Appropriate working environment created (made conducive working environment), Used transparent steel instead of electric light, Prepare/installation of air conditioning system, Prepared waste material stock and trained on sanitation safety Summary The Kaizen implementation given for the 2 enterprises proved productivity and conducive working environment and transforms the enterprises for a betterment of their fruits [The Kaizen implementation
  • 11. increased productivity conducive working environment for both enterprises] The five assets that are implemented are: 1. Sort: identification of inputs for production and service 2. Stabilize: labelling of materials 3. Shining: cleaning machineries 4. Standardize: maintaining the already organized shops 5. Sustain: Space management and keeping modern production flow, skill gap (need assessment and fill the gap, using modern furniture desire) Weakness of the Training Effectiveness problems measured by policy, curriculum, facility of the training materials and equipments training of trainers demand and supply, and market information. Lack of competency for preparing training materials at the grassroots level Up to date facilities and equipment are required Competency of trainers Limited involvement of the private sector and NGOs Limited involvement of the private sector and NGOs, Not providing training on based on demand and supply principle In adequate job opportunities Lack of information. He continued that select an area the first step is to choose where you will conduct your first Kaizen affair. You want to choose an area that will have an impact but not pose too many difficult problems to solve in the beginning. Each event will teach you things that will make the next incident smoother and easier to run successfully. Also, each event provides a training ground for new team leaders. As people gain experience in running events, and as measureable results accumulate in the areas where events have been run, it will become possible to tackle more complex lines and difficult problems. Start slowly and build momentum as you gain confidence and experience. You will get each time you do an event and so will your teams. He further added that, you can choose several areas where you would like to start and compare the merits of each. But during the implementation of the Kaizen event in the selected area the enterprise can disseminate to other work station, and finally the enterprise will have the all compound Kaizen implemented. This will ensure that you start with the best one first, based on several criteria, and help you determine what will be next. Each Kaizen event should be chosen
  • 12. in order to create a progression of results that support the enterprise the implementation of Kaizen. There are a number of things to consider during area selection. We are presiding the work of the Kaizen team; Select the team members, the team leaders’ first responsibility is to select the team members. The team members are the people who actually conduct the kaizen implementation. There should be a maximum of 15 people on the team. Team members must be created depend on the task that each member is doing and also chosen for their ability to work together and also because they understand and support the potential of the kaizen implementation. Those who complain or belittle the potential will slow down or even block success, especially for the first few events you implement. Select the team leaders, after choosing the area and the problem focus for the team leader must be identified. The team leader lead conducting Kaizen; he or she chooses the team members prepare for the Kaizen implementation, creates the schedules, gathers the materials and tools, and follows all event activities, helping with documentation and report we are keeps the team on target, ensuring that they make objectives of the proper implementation of Kaizen. Team leaders we have been assigned that we should have to be selected enough ahead of the implementation so that they can rearrange their schedules to make leading the event their top priority. Prepare the Team Leader, Team leaders will need to know the goals and objectives of the event, the production requirements, and the expectations of team members. Information from past events should be shared with the team leader, such as past problems encountered and gains achieved. What we have to give the team leader should also be given information about what to do in an emergency, safety rules related to the area, what to do when things bog down, how to handle personality conflicts, and where to access needed data. In addition to sustain the team members, the leader has a number of response and activities before, during, and after the Implementation of the Kaizen training. In order to have a big impact right away choose an area, that has activities that occur all over the plant, that has a significant bottleneck or other major hindrance production flow, Where everything is a mess Train the team, Potential team members with a positive outlook may in the fundamentals of Kaizen. All team members and the team leader need to be trained in the methods that will be
  • 13. used or implemented during the event. Team leader is responsible for scheduling and coordinating required training in advance of the event and for provision for the team members to discuss and absorb what they learned. Training will be conducted mainly by the human resources but it can also conduct by the training coordinator and team leader also. Select a problem for improvement, Once the area has been selected, the focus for the kaizen implementation must be decided. Be sure that you mark the boundaries of the chosen area clearly and that you set and maintain the boundaries during the kaizen event. Talk to the people who work in the selected area about the project and work with them in deciding on the problem to be improved. The reasons you chose this particular area for a Kaizen implementation probably included some understanding of what is needed in this area. Now it is time to check your assumptions and examine the conditions and the process used in this area more closely. In selecting a focus for the Kaizen event several things need to be considered. Has 5S been conducted there? Should that be the focus of the first implementation in this area or do you want to implement 5S more gradually before conducting the event? 3. DETME enterprise where found in Gulela Sub-City Woreda 3 proximity to the health canter 4. DOBA/ATW enterprise >> >> >>> >>> >>>> DETME metal and wood production is a private limited company, which is located in Woreda 3 proximity to the health centre and their phone number is 0911431931, they are at the statues of small and micro enterprise with 10 male and 2 female with a total number of 12 shareholders; in addition to this the enterprise creates job opportunity for other employees which are10 in number having 9 male and 1 female members. In terms of employment 7 of them are full time workers while the other 3 are part-timers in the enterprise. The enterprise was inaugurated as of 2006 with initial capital of 1200 birr only. The machinery costs were 84700 and 17000 birr and this contributed a lot in attaining the current capital exceeds to 143184 birr. They applied Kaizen implementation in their enterprise by he help of Entoto TVET Cluster College in 2010.
  • 14. The second one is DOBA and ATW metal and wood production a private limited company, addressed at Woreda 3 aside the health centretheir phone number is 0911650215 level of their statues is small and micro enterprise with 8 male and 2 female and with a total number of 10 shareholders. In addition to this the enterprise has created job opportunity for other workers which constitute 8 male and 2 female members making a total of 10. In terms of employment there are 2 full time workers and 3 part-timers. The enterprise was inaugurated as of 2009 with initial capital of 1200 birr only; but making a great effort after the establishment and with a greater achievement their current capital reached 720,000.00 Ethiopian birr. They applied Kaizen implementation in their enterprise by the help of Ethiopian Kaizen institution in 2012. They were implementing the Kaizen Philosophy properly. Despite their shortage of place for their production, they stick to the stapes and discipline of the system. Since the most of them are educated, their application is proper and their management system revealed a potential for never- ending efforts for improvement in production values. They got an award from Ministry of Science and Technology for their innovation of a machine which produce traditional cloth called “Shma and Tibeb .” The machinery which they innovated reduced production time and created comfortable working environment. Hence, they made modern types of production. The ordinary type of production tools of wavers is traditionally by digging the ground which consumes time and man power. Over all activity and implementation of Kaizen by keeping the procedure in the particular of Kaizen event. presented as follows Even though the service of industrial extension the city administration of A.A particularly in each sub-city and vocational school is started soon; many achievements have been observed. Among such success full accomplishments Kaizen system takes the lion’s share. This system helps this model in association with micro business activity. In addition with this industrial extension gives to those micro-business associations’ short term training to improve their skill business planning and financial management. This service has been implemented in each Woreda and sub-city .Due to this each micro business enterprise has got good progress in their activity. Beside this, the industrial extension gives short term training for an employee and females and enables them to have their job. In this respect Gullele sub-city Woreda 3 have done a good job which can be considered as a model for other sub-cities. The administration creates close contact
  • 15. with Vocational Schools to bring more trainers to be trained and finally enable them to start their Micro Business services. Moreover, they also create contact with different NGO’s or Charity Organizations to create good job opportunities for the trainees. Generally, the management has made good progress in this year than the before. The overall activities of that industrial extension can be stated as follows:  A new machinery is donated to them, and  The administration enables them to buy a new machine and begin their service that is three Micro Finance enterprises each having 20 members has bought a machine with 25,000,000 Eth birr. The coast doesn’t include the saving account which is given to them by saving and credit association of Addis Ababa. Activities Performed Through Kaizen The first and second round activities have been implemented for DTAM and Ras Emiru through Kaizen Systems. We did it basically with their own ------------.Now we are following their activities and still the following activities has been performed:  Shape layout  Preparation of materials according to shop lay out  A decision was made on having a new tool store have been implemented.  Re-arrangement of raw materials.  Room partition.  Arrangement of Chair, table and Shelf.  Arranging raw materials in accordance with quantity and ---------  Seat arranged raw material in tool store.  Cleaning materials with comprador and Dicdel  Identifying problems of dysfunctional materials.  Room cleaning  Kaizen board.  Trashcan(Garbage)  Stick quotations in timber.  Training in auditing.
  • 16. Benefits of Kaizen  The process of finding material takes 10-15 minutes before arrangement, materials hidden and poor -------cleaning  Hidden materials found, creates conducive environment and time will be saved.  Problem of installation will be solved.  After installation conducive, visible safe environment will be created.  The ware house re-arranged and all materials situated In a clear visible area.  Garbage prepared and situated in a specified area. Expenditure for purchasing materials  Broom  Electrical materials such as Conduct breaker  Half kilo 5cm and 8cm nail purchased. The income was high after Kaizen implemented because pieces of metal scrap sold.  Filling the gap by giving training such as filling, auditing management.  Sanitation undertake, first aid box a bounded plan pre pared. such plans are:  Outcome which is planned monthly  Selling plan  Cash flow plan  Support given for those who need help Concerning the enterprises implemented Kaizen continues follow-up support Among the works in this year visiting, observing and assessing enterprises and associations which implemented Kaizen such as Lalibella, Raccon, DETEMA wood and metal enterprise. Accordingly: 4. Lalibella Wood and Metal Enterprise Strangth: Place of the machine, organized office, cleanliness, their work flow is work centered
  • 17. Drawback: hand tool raw materials, Kaizen boards are twisted, misplaced in unproperplace Support: Give help, advice in order to arrange sitting materials in proper way. 5. Rlaccon Wood and metal enterprise Strength: cleanliness Drawback: Manufacturing wood and metals products together misusing flow of work (is not work centered), no Kaizen board, unwillingness of accepting expertise advice and support. Support: give advice to --------working rooms, give expertise support such as cleanliness of work place. 6. DTM wood and meals Enterprise Strength: Organization using the office is better, Work flow and cleanliness of shade. Draw back: Misuse of raw materials and improper placing of hand tools. Support: give advice for placing raw materials and hand tool Regarding of the training Industry extension within 6 month of Kaizen implementation, short term training of women and unemployed in entrepreneurship conducted with the cooperation of TVETs in the first, second and third round. After training conducted the trainees were organized in association and start operation .Trainees are: In terms of first round training: The aim was to train 500 unemployed trainees, but 402 of them were trained in different fields in Entoto and Shro Meda Technical and Vocational College. Measurement Plan Accomplishment in % People 500 402 80.4
  • 18. Trainees Data in the First round No. Training Field Male Female Total No. 1. Electricity 25 14 39 2. Ceramic 12 2 16 3. Sanitary 4 2 6 4. Block product 43 34 77 5. Food Preparation 11 43 54 6. Laundry 3 7 10 7. Chemical Process 2 8 10 8. Sewing 9 42 51 9. Wood Work 14 3 17 10. Metals 6 3 9 11. Leather 8 15 23 12. Authomechanic 7 3 10 13. Barbering and House hold 39 43 79 Total 189 213 402 Among the trainees of 402, 57 Male and 112 Female with a total number of 169 were embraced in 11 associations. The following table shows name of associations and field of occupations NO. Name of Association Field of Occupation Male Female Total 1. Ertale Blocket 20 0 20 2. Unity Blocket 18 2 20 3. Entoto Blocket 11 9 20 4. Emmy Barbering Hair dressing 0 10 10 5. Aser Abebawoch Hair dressing 0 10 10 6. Fertuna Precast 8 2 10 7. Edeget Laundary 0 12 12 8. Edget Leather 0 17 17 9. Enchet Sera Wood Work 0 10 10 10. Fast Food Food Preparation 0 15 15
  • 19. 11. Food Preparation Food Preparation 0 25 25 Among the organized association three Blocket and Precast associations began production with 37 Male and 13 Female and a total number of 50 members. No Name of association Field of occupation Male Female Total 1. Unity Blocket 18 2 20 2. Entoto Blocket 11 9 20 3. Fertuna Precast 8 2 10 The plan was to train 165 Males and 135 Females with a total of 300 unemployed, but 164 trainees of which 96 Males and 68 Females gained the training. Measurement Plan Accomplishment in % People 300 164 61 Details of the Trainee No. Field of training Male Female Total 1. Blocket 42 37 79 2. Building 6 5 11 3. Ceramic 7 4 11 4. 11 6 17 5. Electricity 19 3 22 6. Wood work 7 3 10 7. Leather 8 10 18 8. Metal 15 0 15 9. Sewing 1 3 4 10. Sweather 3 3 6 Total 116 74 190
  • 20. Among the trainees who have taken the training 3 associations were organized namely: No. Name of Associations Field of occupations Male Female Total 1. Yenegew Tesfa Blocket 9 14 23 2. Zaf Electric Instalation 12 0 12 3. Jantekel Blocket 9 15 24 Total 30 29 59 From second round trainees those good grade scorers are 51Males and 44 Females with a total number of 95 peoples have got their job in different Enterprises. No. Name of institutions Occupations Created job opportunit ies Male Female Total 1. Anbessa Shoes Leather 29 28 57 2. Ramsay Shoes Leather 10 16 26 3. B & C Allumium Metal 5 0 5 4. Detame Wood &Metal 5 0 5 5. Private Electric Installation 2 0 2 Total 51 44 95 Third round training Initially it was intended to train 115 Males and 85 Females with a total sum of 200 unemployed. Out of these 97 Males & 79 Females totally 176 trainees took the training on different fields.
  • 21. Measurement Plan Accomplishment in % People 200 176 88 Details of the Trainee No. Field of training Male Female Total 1. Leather 8 35 43 2. Building 4 0 4 3. Ceramic 10 3 13 4. Wood work 13 7 20 5. Pipe 2 0 2 6. Metal 18 0 18 7. Blocket 27 33 60 8. Electric 15 1 16 Total 97 79 176 N.B. These do not include Entoto graduates. Cobblestone Trainees who have got job. No Field of Trainee Name of associationation Male Female Total 1. First round Tenker Cobblestone 11 0 11 2. Second round Hand to Hand Cobblestone 15 8 23 3. Fourth round Natnael cobblestone Kenenissa cobblestone Bonsa cobblestone Kenenissa cobblestone 15 18 18 18 3 0 0 0 18 18 18 18 4. Fifth round Semen cobblestone 56 0 56
  • 22. 5. Eighth round Yenegew Sew cobblestone Ras Michael cobblestone HaHu cobblestone Sefera Genet cobblestone 13 15 19 3 7 5 4 2 20 20 23 5 6. Ninth recruited 28 25 53 Total 234 54 288 The coordinators work leaders got private plan beside 1 to 5 plans and a check list.Additionaly time is allocated for meetings to assess---------.During second round there was no attitude gap in institution level because problems identified and solved in the first round training. Training is conducted deliberately and trainees working privately, in factories and also in associations. Kaizen Workshop management, bussness plan, work ethics, leadership, resourse management ------plan preparations credit and service, book keeping, market competency ,trainings given by Vocational schools. The training conducted by two rounds. The first training conducted in the first two days but the second round was wider and it takes 1 week. The training was vital to fill the gap. Regarding the input more or less there had been no shortage excluding Computer and table. A ground plus 4 building is underway by world Vision .The operation was lagging behind due to absence of Engineer, but now the contractor hired engineers and the building process is taking place on a large scale. In addition to this the charity organization is willing to help organized trainees. Namely: 5. Unity Blocket Enterprise Private Limited Company with 15 members. 6. Yenege tesfa Blocket Enterprise Private Limited Company with 23members. 7. Entoto Blocket Private Limited Company with 20 members. 8. Jantekel Blocket Private Limited Company with 20 members.
  • 23. And the total number of these associations is 78.After they organized themselves in associations they requested to be aided by the following materials;  Blocket production machine  Plastic pipe  Spade  Spoon for concrete mixing  Glove  Wok uniform  Timber  -----  ------  -------  ------- This was presented for the charity organization with specification and they are waiting for the purchase and delivery of the materials to begin their work. In Shro Meda Training institution all the materials were purchased by World Vision. For all departments machineries and accessories were purchased and the remaining is on process, specifically for leather department many types of machinery were bought, but machineries for shoe manufacture are not still purchased. Document exploration These reports were obtained from Entoto Polytechnic Cluster College for research purpose. The main aims of this study was to investigating the problem happened before one year from this document exploration you can easily identify how far wrong report mislead the top management. One can also easily identify from this document unexpected work done by Kaizen teams the report indicate that how far the Kaizen team did several things like additional space got during implementation, production improvement and since the presentation was only focused orally on the weakness parts of the newly employed workers as expressed on the case questionnaire.
  • 24. The document investigation found that under the problem parts of the college document i.e. (A) “Failure to actively involve newly selected members of the implementation group from the college and woredas. (B) Unable to recruit qualified employees for the jobs. Entoto Technical and Vocational Education and Training College Ref. No. Et/C/4157/7/6 Date 7/5/04 Addis Ababa Technical and Vocational Education and Training Agency Industrial Extension and Technology Transfer Main Job Process Addis Ababa Subject: Report of Support for Gulele sub city small and micro enterprises Support given by Entoto Technical and Vocational Education and Training College in collaboration with the agency to 12 selected small enterprises from Gulele sub city on:  Production quality and improvement  Technical Skill training  Job creation and management  Technology capacity building The list of activities by the support group from Tahisas 16/2004 to Tere 4/2004 explained in 10 pages is attached to this letter. Sincerely Deans Office CC Industrial Extension and Technology Transformation Main Industrial Extension Service main
  • 25. Addis Ababa Entoto Technical and Vocational Education and Training College Industrial Extension and Technology Transformation Job Process implementation group identified the following attitudinal, skill, resource limitations and corrective measures with their outcomes on the support to 12 selected small and micro enterprises in Gulele sub city. Operational fields of the12 selected enterprises  Metal works----------------2  Wood works----------------4  Construction----------------1  Food Preparation-----------5 Structure of the target enterprises  Association-----------------12 Enterprises  Group------------------------ None  Private-----------------------None Reasons for selection  They are model enterprises  Feasible to give Cooperative Training For TVET trainees  132 employees participated in the 12 enterprises from which 45 of them are females  All have taken industrial extension service giving training Table 13: List of the Model Enterprises of the name of selected enterprises locations fields of operations, structure and numbers of employs. Appendix 1 Table 13 Management practices data related to practice of Kaizen in the enterprises Problems identified by the implementation group. Lists of the modal enterprises List of the Model Enterprises Problems identified by the implementation group Attitudinal
  • 26.  Time management problem on entry and exit time  Failure in planning certain activities and inability to prepare necessary resources in advance  Members of the implementation group are new to the activities which leads to loss of confidence Skill limitations  New members are not familiar with job  Coordination problem during commencement  Lack of a trainer for Tapestry training Resource  Failure of the enterprise in providing the necessary resource at the right time which leads to delay and compromised quality  Unavailability of a training module prepared in Amharic language for the less educated trainees  Failure to give trainings based on resource plans  Unavailability of a professional level document for tapestry training  Failure to provide safety garments and other equipment Problems identified from the enterprise Attitudinal  Failure in providing the necessary resource at the right time  Failure of employees to take trainings and make it business as usual  Reluctant to disclose their income and expenses  Unable to work according to the established system  Being absent from work for different reasons Skill  Limitation in preparing business plan, business management and procurement management  Limitation in accounting knowledge and unwilling to hire a professional  Limitation in the skill of machinery handling and protection  Lack of skill in the various machinery operating techniques  Limitation of knowledge in galvanic collision Resources
  • 27.  Poor quality machineries, lost their safety parts  Unavailability of safety materials (dust proofs, helmets, uniforms)  Scarcity of tools  Sanitation problem Problems from the coordinating party  Limited number of trainers  Corrective suggestions which are not based on supervision  Failure to actively involve newly selected members of the implementation group from the college and woredas  Unable to recruit qualified employees for the jobs Activities performed to solve the problems from the implementation group  Attitudinal  Reached agreement with all members on punctuality by trying to avoid the factors affecting time management, using other possible options in cases of transportation problems  With a relentless effort from the implementation group, the problems are evaluated and solved  Skills  They are made to observe experienced implementation group members and work accordingly  It is programmed in to prepare plans in advance and assess daily activities to solve the problem of coordination Solutions from the implementation group  Resources  A training on business planning and management is given on the work sites with available resources where all equipment and machineries are not fulfilled  In association with other trainers, previous training manuals are found, a new Amharic training module is prepared and the training is given  Despite the fact there is no professional level for Tapestry, better methods for efficient use of resources for the work is suggested Solutions from the implementation group  Attempts to fill gaps by establishing a system in which informed parties let know others
  • 28.  Training are conducted with the use of available resources in trying to make it standardized Solutions for the problems from the enterprise  Attitudinal  Creating awareness on the scope of support to avoid dependency, getting material support from the college for which the enterprises pay and convincing them to own easily available materials.  Trainings are given to the less active employees and they are made aware of their roles  Trainings are given that change their attitude and enable them establish a consistent working system  Skill  Necessary resources are gathered to fill the gap of skills based on the given professional standards  Business management and machinery operation trainings are given Trainings are given on the association’s work site  Metal works and assembly technique trainings are given in workshops Resources  Some machineries are maintained with capacity of the implementation group and safety panels are produced  Some of the enterprises are using uniform workshop garments while processing to purchase other safety tools Outcomes  With regard to productivity increment  Unlike before, workshops and machineries are organized in a structural way to ease production  Leaving a conducive working space suitable for proper production  Some dark workshops using electricity convert their roofs to transparent roof sheets which enables them to save electric power  Ventilating the workshops and made them conducive work environments  Waste storage bins are prepared to keep workshops clean and shop sanitation trainings are given Entrepreneurship and skill development trainings  Business plan preparation trainings are given and members are made to prepare their own business plans
  • 29.  Entrepreneurship trainings are given  Accounting training is given Technical skills training  In relation to wood works, personal and machinery safety trainings are given  Wood work training is given  In relation to metal works, trainings on galvanic collision and parameters affecting galvanic collision are given Technological capacity building  With regard to technological support, a portable chair imported from Indonesia is disassembled, designed and made from local pieces of woods which decreases the cost of the chair which is been introduced to enterprises. Outcomes for each enterprise 1. Kidist Mariyam wood works  Shop width 150 m2  Extra space which obtained after implementation 30 m2  Expense for implementation 500 ETB  Income from by-products (scrap) 300 ETB  Support of Electric installation in ETB 1000 2. Ralkon Metals and woods  Shop width 200 m2  Extra space 60 m2  Expense for implementation 500 ETB  Income from Waste 3000 ETB  Support of Electric installation in ETB 1000 3. Addis Kidan Construction  Shop width 200 m2  Extra space 60 m2  Expense for implementation 1500 ETB  Income from Waste 500 ETB  Support of Electric installation in ETB 1000 4. Nib Household and Office furniture  Shop width 200 m2
  • 30.  Extra space 60 m2  Expense for implementation 1500 ETB  Income from Waste 300 ETB  Support of Electric installation in ETB 1000 5. Lalibela wood works  Shop width 140 m2  Extra space 50 m2  Expense for implementation 1500 ETB  Income from Waste 1000 ETB  Support of Electric installation in ETB 800 6. AbroAdegMetals and woods  Shop width 180 m2  Extra space 60 m2  Expense for implementation 1500 ETB  Income from Waste 200 ETB  Support of Electric installation in ETB 150 7. Addis MerafPacked Foods  Shop width 150 m2  Extra space 45 m2  Expense for implementation 50 ETB 8. KimshaPacked Foods  Shop width 150 m2  Extra space 45 m2  Expense for implementation 50 ETB 9. TesfalakalGudateghochPacked Foods  Shop width 180 m2  Extra space 50 m2  Expense for implementation 1000 ETB  Support of Electric installation in ETB 2500 10. Harina Packed Foods  Shop width 90 m2  Extra space 30 m2  Expense for implementation 800 ETB
  • 31.  Support of Electric installation in ETB 2000 11. Godana  Shop width 180 m2  Extra space 90 m2  Expense for implementation 50 ETB 12. AmbagerPacked Foods  Shop width 200 m2  Extra space 80 m2  Expense for implementation 2500 ETB  Income from Waste  Support of Electric installation in ETB 3000.