11. Kaizen : continuous improvement for a better
5S: The first, simplest and fundamental Kaizen step
5S: based on continuous improvement, as applied to
one’s workplace.
Trains employees and management to systematically
implement change.
After 5S, company is ready for higher level Kaizen
activities.
12. Cleaner, Safer, well organized work place
Smoother and systematic workflow
Make work easier, faster and reduce
errors
Less ‘waste’ (time, effort, materials etc)
Make problems visible. Detect small
problems before it become bigger.
Give good impression to visitor ; customer,
auditor, supplier, etc.
If no measurable improvement, we have
not really done 5S (only decoration!)
Efficiency
Quality
Safety
13. “A company that cannot successfully implement the 5S’s cannot expect
to effectively integrate JIT, re-engineering, or any large-scale changes.
Good workplaces develop beginning with the 5S’s.
Bad workplaces fall apart beginning with the 5S’s.”
-HIROYUKI HIRANO-
15. To sort and systematically discard items that are
not needed in the workplace.
• Create more space.
• Separate necessary & unnecessary items
• Reduce time waste in searching item.
• Eliminate unnecessary work in handling
unnecessary items.
16. • Change in sales @ production plan.
• Excessive or incorrect ordering.
• Habit of storing.
• “Sayang” or sentimental value.
• Not dare to dispose.
• No system for disposing item.
• Improper storage location /method
• Aged @ obsolete machines & equipment
• Damage by improper handling @ storage.
Cause of item accumulate
17. • Color tag @ label to indicate unneeded &
unsure items.
Red Tag
• For dispose assets & valuable items.
Scrap Notice
• List of unnecessary items found during audit.
Audit
• List of old items based on expiry date or time
period.
Age-list
• Conduct seiri as a team involving all member
at a fixed time.
Gotong-royong
18. 1. Immediately dispose any unwanted items (non value).
2. For value item @ un-sure items :
Red Tag & separate.
Report to Superior / Department HOD / 5S committee.
Take action as per instructed.
If no decision after 1 week, transfer item to “Seiri Area”.
Area / Machine PIC responsibility
1. Tag any unwanted items.
2. Note in audit checklist.
3. Follow-up during next audit either action has been taken or not.
Auditor responsibility
19. 1. Gather / collect all seiri item at designated “Seiri Area”.
2. 5S Committee @ Management need to make decision to :
Recycle @ re-use
Repair @ modify
Sell @ give away
Dispose @ destroy
3. Take action.
4. Repeat once per year (minimum).
What to do with Seiri Items
23. (SEIRI) TAMM-5S-001 :
RED TAG
Objective : To identify unnecessary/unsure items in the
working area
Procedure :-
1. Identify items to SEIRI. 1 TAG for 1 ITEM
2. Fill the required details in the Red Tag (except for
action and approval columns)
3. Record the information from Red Tag into the 5S
Red Tag Log
4. Red Tagged items must be claimed within (1) week
& must be approved by HOD.
5. Any Red Tagged item left @ not being claim after
(1) week must be transferred to Seiri Area
6. 5S Committee will conduct monthly audit to Seiri
Area and decide the next course of action.
7. The maximum period for items stored in the Seiri
area (LEFT AT IT IS) is 1 YEAR. Expired items
without any action may be removed automatically
by the 5S Committee.
25. To arrange items in a neat & systematic manner for easy
retrieval & easy return after use.
1. Safety : increase safety
2. Efficiency : make work easier & faster
3. Neatness : Workplace more organized & look neat.
26. 1. Follow First In First Out (FIFO) method for storing items.
2. Each item need a dedicated location.
3. Each location & items should be label systematically.
4. Place item so that they are easily visible to minimize search time.
5. Achieve 30 seconds retrieval time for all items.
6. Separate rarely use item from frequently use items.
7. Place frequently use items at the point of use @ within reach of user.
7 Seiton Efficiency Principles
How to
Seiton
36. Before 5S After 5S - Cleaned, organized and drawers
are labeled (less time and frustration
hunting)
37. Objective : To shown the person in charge responsible on managing all 5S
activities in that particular location / area.
Procedure :
1. Each Department to assign
1 staff as Area Owner in each
area in charge
2. Use the standard format :-
Size : 10cm x 6cm
Background : White
Font : Arial (Black + Bold)
Laminated.
Attached PIC photo.
3. Paste at the top right side of the
door / cabinet / board.
PIC
5S
(DEPARTMENT)
(LOCATION)
(PIC NAME)
(WORKER’S NO.)
10cm
6cm
(SEITON) TAMM-5S-002 : AREA
OWNER
What are Area Owner responsibility?
To in charge all 5S activities for the
area
To prepare cleaning schedule
To carry out Red Tag activity
38. (SEITON) TAMM-5S-003 : LINE &
LABEL STANDARD
Label
Label
Ruang gap antara
garisan & item ;
0.5 ~ 1.0 inciC
Gap between
item & tape
0.5” ~ 1.0”
Line & Label Style 1
Label size/Font Style:
Floor (24mm(H), Font : Hel, Size :
24)
Table (12mm(H), Font : Hel, Size :
48)
Tape size
Floor : 2.0”
Table : 1.0”
Line & Label Style 2
Objective : To identify, marking & specify
a storage location for each item
(on the floor/table)
Line / Tape Color Coding :
Label must be printed using a label printer
Background = White
Font = HEL (Black + Bold)
Wording : ALL CAPITAL LETTERS
(General)item location
Schedule waste item only
Safety equipment/
Electrical panel
39. Line / Tape Size
Floor = 2.0”
Table = 1.0”
Don’t put any
item in this
area!!!
(SEITON) TAMM-5S-003 : LINE &
LABEL STANDARD
OR
40. (SEITON) TAMM-5S-003 : LINE &
LABEL STANDARD
Document Tray Label:-
Label must be printed using label printer
Must include “IN”, “OUT”, “KIV”
Label tray position (which suitable):-
1. Facing the owner
2. Facing to outward
IN
OUT
KIV
1st Level
2nd Level
3rd Level
For approval/review
To distribute/
For filing
Pending/To confirm
Label size/Font Style:
(24mm(H), Font : Hel, Size : 48, BOLD)
Note : All label must be written in CAPITAL LETTER
41. Objective : To increase work process efficiency.
Arrangement for working desk
must follow standard layout.
Only these item are allow to be left on
top of working desk ;
i. Laptop / Monitor / Keyboard / Mouse.
ii. Tray
iii. Telephone, calendar & Stationery
(SEITON) TAMM-5S-004 : WORKING
TABLE ARRANGEMENT
Telephone
calendar &
stationeries
Safety
helmet &
bag
42. <<During work>>
Only items/documents related to current task to be
on the desk.
Arrange all items & documents properly & neatly
before leaving table
No items @ files should be on the floor
Push the chair into the desk when leaving the table
<<After work>>
Properly close the laptop and place it in front of the
monitor/middle of the table
Make sure only the allowed item left on the desk.
Keep documents/files/other items before going home.
During work
After work
(SEITON) TAMM-5S-004 : WORKING
TABLE ARRANGEMENT
43. Don’t put / hang anything to the chair or
surrounding the work desk.
Only bag & safety helmet is allowed to be store
under the work desk.
Make sure all cable & wires are managed neatly.
Common table – Sharing items on the common
table must be labelled and zoning
(SEITON) TAMM-5S-004 : WORKING
TABLE ARRANGEMENT
44. ① Solo/Manager work desk
Calendar/
Stationerie
s
(Working area)
- Laptop,
- monitor,
- keyboard,
- mouse
(SEITON) TAMM-5S-004 : WORKING
TABLE ARRANGEMENT
45. ② Adjoin work desk
Calendar/
Stationerie
s
(Working area) - Laptop, monitor,
keyboard, mouse
(SEITON) TAMM-5S-004 : WORKING
TABLE ARRANGEMENT
46. ③ Confront work desk
(SEITON) TAMM-5S-004 : WORKING
TABLE ARRANGEMENT
Calenda
r/
Statione
ries
Calenda
r/
Statione
ries
47. ④ Four work desk
(SEITON) TAMM-5S-004 : WORKING
TABLE ARRANGEMENT
Calendar/
Stationer
ies
Calendar/
Stationer
ies
48. Example of working table arrangement in a department
(SEITON) TAMM-5S-004 : WORKING
TABLE ARRANGEMENT
Calendar/
Stationer
iesc
Calendar/
Stationer
ies
Calenda
r/
Statione
ries
Calenda
r/
Statione
ries
Calenda
r/
Statione
ries
49. Objective : To make the searching
& identifying of files more efficient.
Arrange file based on file numbers;
from left to right
Place the Index at the top left (right
door) of the cabinet
LABELLING
TAMM-5S-006 CABINET FILE
INDEX
File number
1) Dept. colour
code
2) Department
1) File title/
description
2) Font : Arial,
Size : 26
1) Volume no.
2) Sub colour code
(department)
101
Example of file no.
(Font : Arial, Size : 12)
Cabinet
No.
File
sequence
no.
Vol. 1
Department Colour Code
Font : Arial/Colour : Black
(Bold)
Size : 72 or which suitable
Year
Month
50. A. 532
A 5th file located in QA’s 3rd Cabinet
Placed in 2nd shelf. What is the file number?
B. 305
C. 325
D. 352
B. 305
51. Example of cabinet labelling (Full Height Cabinet – with door)
Label for cabinet:-
1) Area owner (HOD)
2) File index (document
files kept in the cabinet)
(SEITON) TAMM-5S-006 CABINET FILE
INDEX
52. Example of cabinet labelling (Full Height Cabinet – without door)
Side view
(SEITON) TAMM-5S-006 CABINET FILE
INDEX
53. Example of cabinet labelling
(Half Height Cabinet – with door)
Example of cabinet labelling (Half Height Cabinet – without door)
Side view
(SEITON) TAMM-5S-006 CABINET FILE
INDEX
54. (SEITON) TAMM-5S-007 METER GAUGE
LABELLING
Objective : To detect any abnormality visually
Procedure : colour indication
1. 2 colours – Normal/Abnormal
2. 3 colours – Normal/Control/Abnormal
Example of metre gauge colour label indication
3 colours
2 colours
56. To clean & inspect the workplace thoroughly so that there
is no dirt on the floor, machines & equipment.
• Increase safety.
• Create comfortable work environments.
• Easier to identify abnormal @ problem.
• Detect small issue before it become big problem.
57. 4th Class
Workplace
•People make
mess
•No one cleans
up.
3rd Class
Workplace
•People make
mess
•Other group of
people who
cleans up.
2nd Class
Workplace
•People make a
mess.
•Cleans up by
themselves
1st Class
Workplace
•Nobody make
mess.
•Everyone
cleans up.
4 Level of Housekeeping
58. How?
Keep clean all the
time.
Keep clean as you
work, don’t wait
until after finish
Cleaning = Inspection.
Identify problem & rectify.
Don’t just dust away visible
areas only.
Daily cleaning.
Cleaning is part of work.
3-10 minutes before/after
work to clean & inspect
Best cleaning method.
Best method,
suitable tools
Not necessary the
easiest method
Clean the difficult areas.
Difficult to see ; top,
bottom, back, gap, etc.
Difficult to clean.
These areas must be
included in cleaning
schedule.
Cleaning tools.
Must be clean &
arrange properly.
Suitable with
cleaning method.
Success key:
Clear responsibility
Complete cleaning
schedule (who/when/how)
59. • Identify source and eliminate it
• If not possible, modify to carry
away dirt
Prevention
• Contain dirt/leakage to specific
area
• Clean regularly
• Do not allow dirt to spread
Containtment
• Comprehensive cleaning
schedule
• Good cleaning methods
Regular
Cleaning
SEISO STRATEGIES
60. Forklift FL01 PIC : Abu
Frequency Day/Time
Area /
Machine
Method PIC
Daily 8:30am – 8:40am Forklift
- Inspect as per checklist.
- Clean driver / seat area.
Mat
Weekly
Sunday
8:40am – 9:00am
Forklift
- Inspect battery, oil, water,
tires.
- Wipe & clean all areas.
Yope
Monthly
Last Sunday
4:00pm – 4:30pm
Forklift
- Wash.
- Clean engine with
degreasing agent.
John
Yearly
End of Jun
End of Dec
Forklift - Maintenance Service. Contractor
Sample of Cleaning Schedule.
65. Seiri
•1.Throw away
garbage
•2.Sort out and
take out any
unnecessary items
Seiton
1.Always return
tools @ equipment
back to its location.
2. Make sure all
item has its own
storage location.
Seiso
1.Daily cleaning &
checking as per
schedule
2.Keep clean
environment even
during working.
DAILY 3S – SEIRI + SEITON + SEISO
66. (SEISO) TAMM-5S-008 CLEANING
SCHEDULE
Objective : To plan & organize cleaning activities in the area/machine
Procedure :
1. Area owner or HOD prepare the cleaning schedule
2. All staff perform cleaning activities in each area/machine involved
3. Audit by Area Owner or HOD
Cleaning Schedule for Meeting Room 1 Area Owner : Nisa
Frequency Day/Time Description PIC
Daily 8:30am – 8:40am
- Clean the whiteboard
- Arrange table/chair
Nisa
Weekly
Every Sunday
8:30am – 8:40am
- Vacuum/Mop the floor
- Wipe table/chair
Cleaner
Monthly
Every 1st Sunday
monthly
8:30am – 9:00am
- Check window, door, and other
equipment; projector, clock, etc
- Clean difficult to see area
Nisa
Yearly
Every 1st Sunday in
year
8:30am – 9:30am
- Seiri activity
- Check all furniture
- Arrange for maintenance if necessary
Nadia
68. To create & maintain high standard of workplace by
keeping everything clean & orderly at all time.
• Establish visual control systems.
• Clear guideline / SOP for all to follow.
• Clear understanding & information sharing.
• Improve operation & workflow.
69. 1. Repeat 3S daily and improve
2. Prepare & implement 5S Standard Guideline
o Prepare by Committee @ Management.
o Implement & follow by all.
3. Color coding & labeling.
o Use standard color code & label format.
4. Before vs after photos.
o Record & report.
o Can also be use as a guideline.
5. Checklist.
o Confirmation & evaluation.
6. Audit & Patrol.
How?
70. Confirmation
Checklist Evaluation
Checklist
• Based on Yes / No.
• No rating system.
• Easy to use.
• Suitable for daily / weekly
audit.
• Not good for comparison &
improvement.
• Based on rating/score (1-5 @ 1-10).
• Clear rating system.
• Each level / mark must have clear
criteria.
• Suitable for monthly audit &
competitions.
• Good for continuous improvement.
71. Item
Self
Audit
PIC /
Superior
Audit
5S
Committee
Audit
Management
Audit
3rd Party
Audit
Who to
conduct?
Self
PIC &
Superior
Committee
Member
Senior
Management
Customer /
Independent
How often? Daily Daily Monthly Random
Upon
demand
When to
conduct?
Before
start
work
Random Schedule Random
Upon
demand
Use
checklist?
No No Yes No -
Others
Report &
follow-up.
5S Audit
72. Before after pictures displayed and used as
reference
Pictures with points highlighted for emphasis.
Pictures used as checklist
STEP 1 STEP 2
5S Before & After Pictures
73. (SEIKETSU) TAMM 5S Y2020
COMMITTEE
Mikio Omori
Chairman
Yasuhiro Sahashi
Coordinator
(QA) Wan Ismail Hilmi
Leader
5S Promotion
(QA) Hidayah
Takayoshi Miyano
Advisor
5S Audit
(PR) Syimma
5S Guidelines
(LO) Azharuddin (FA)
5S Training
(HR) Nadia (HSE)
(AF) Afura
Secretary
TAMM 5S
GUIDELINE
S
74. (SEIKETSU) TAMM 5S Y2019
AUDIT RESULT
RANK Department Total Mark (%)
1 HR& GA 61.53
2 LOGISTICS 53.20
3 PRODUCTION 51.70
4
ACCOUNT &
FINANCE
49.73
5 QC/ISO & HSE 48.57
6 FACILITY 45.13
Y2020 COMPANY OBJECTIVE
100% STAFF INVOLVEMENT
70% 5S AUDIT SCORE
80% 5S QUIZ/EXAM SCORE
81. To train people to practice 5S system continuously so
that it becomes habitual & deeply ingrained in working
culture.
• It becomes a working habit.
• Develop discipline & team spirit.
• Enhance operation effectiveness in a better
working environment.
82. Training
•5S awareness &
knowledge
•Interest in 5S
Lead by example
•Start by me
•Self discipline
Team work
•Management -
employees
•Team effort
Bulletin &
newsletter
•Info & 5S progress
•Notice board, 5S
corner
Reward & recognization
•5S project/competition
•5S audit
JANUARY
How to
Shitsuke
87. WHAT TO PROPOSE IN
KAIZEN?
Production
Facilities
Safety/
Security/
Environmen
t
Office
work
Products
Quality
Proposal which only
includes complaints,
ambiguous in contents,
related to staff benefit will
NOT BE ACCEPTED!
90. WHO WILL REVIEW/EVALUATE
THE KAIZEN IDEA?
GENERAL MANAGER
Final Evaluation
PLANT SV & MANAGER
Secondary Evaluation
PROMOTER
Primary Evaluation
Appreciation – Grade 4 Grade 3 – Grade 1
Chairman
Committee
Members
Department
in Charge
(GA)
Kaizen
Committee
Meeting
91. Q1 : DO ALL KAIZEN PROPOSAL
ARE IMPLEMENTED?
• Proposal evaluation
• Implementation
• Award based on grade
Good idea, necessary
• Appreciation award
• Not implemented
Not implemented, good
idea, show effort
• Appreciation award
• Research
• Not necessary : finish
• Necessary : implement &
re-evaluate, award deduct
from previous award
Good idea, need
more details
• Appreciation award
• Research and presentation
• Committee meeting
• Award & certificate
• Award deduct from
previous award
Very good idea,
Grade 1-3
• Only for appreciation award
proposal
• Submit re-evaluation
• Re-evaluation
• Award deduct from previous
award
Not necessary
Necessary
92. Q2 : HOW AND WHEN THE PROPOSAL
IS RE-EVALUATE?
1st
Submissio
n
• Not implemented
• Appreciation award
1) Case/Time
Necessity
2) Research &
Implement
• Necessary
• (eg: Weight
bridge, phone locker)
& implemented
• Research, effective,
implemented
Re-
evaluation
• Submit re-
evaluation after
implementation
completed
• New award deduct
from paid award
before
93. Q3 : CAN WE SUBMIT KAIZEN FOR
OTHER DEPARTMENT?
Answer : Yes
Proposal
submission
Promoter review
the proposal &
HOD advise for
implementation
department
The proposal to
be evaluated by
implementation
department.
Promoter
Manager
HOD/GM define
the necessity of
the proposal and
evaluate
Proposer–Promoter
(Proposerdepartment)
Evaluationbypromoter
(Proposerdepartment)
EvaluationbyManager
(Implementdepartment)
EvaluationbyGM
(Implementdepartment)
94. Q4 : HOW CAN OTHERS ACCESS FOR
APPROVED KAIZEN?
•Documal (Document List Kaizen
Program)
•Common Server (00-Kaizen Program
0-Approved Kaizen Proposal)
Soft Copy
•Office Library (Training Materials)
Hard Copy
97. EXAMPLE OF KAIZEN PROPOSAL –
KAIZEN FORM
①
Proposer Details
Name : Zain
Staff ID : 0255
Dept : Facility
Proposed Date :
31/12/2020
Implement Dept :
Facility
②
Title : Key Box
Management at
Maintenance
Workshop
③
Before Kaizen:
-No key management
at Maintenance
Workshop
-Take time to find key
needed
-Not aware if key
loss/not returned
④
After Kaizen :
-Key are systematically
managed
-Safe time to find key
-Easy to trace lost/not
returned key
[Rev.2]-01032019
98. EXAMPLE OF KAIZEN PROPOSAL –
ATTACHMENT
CURRENT CONDITION AFTER KAIZEN
-No key management
-Take time to find key needed
-Not aware if key loss/not
returned
-Key are systematically
managed
-Safe time to find key
-Easy to trace lost/not returned
key
1) Before & After Kaizen picture/condition 2) Estimate cost/online price/quotation
3) Others
Propose location:
At the Workshop
entrance
100. TOTAL NO. OF APPROVED KAIZEN
PROPOSAL AND KAIZEN AWARD
RECEIVER 2017-2019
Year
Award Receiver
(Department)
% from Total
Proposal
2017 HR & GA 10/32 = 31.3%
2018 Production 26/72 = 36.1%
2019 Facility 64/186 = 34.4%
Company Objective FY2020
130 Approved Kaizen Proposal
60% of Kaizen Implementation
As 30 September : 118
approved Kaizen
2017, 32
2018, 72
2019, 186
2020, 191
0
50
100
150
200
250
2017 2018 2019 2020
No.
of
Approved
Proposal
Total No. of Approved Proposal
Target 2019 : 80
Target 2020 : 130
101. TOTAL NO. OF APPROVED KAIZEN
PROPOSAL BY DEPARTMENT
(JAN 2019 – DEC 2019)
Total number of
Approved Kaizen
Proposal
(Jan 19-Dec 19)
186 proposals
PR FAC LOG HSE QA HR ACC
2019 44 64 13 10 1 32 22
0
10
20
30
40
50
60
70
TOTAL NO. OF APPROVED PROPOSAL
102. PERCENTAGE OF IMPLEMENTED
KAIZEN BY EACH DEPARTMENT
(JAN 19-DEC 19)
Percentage of
Kaizen Implementation as
at 15/Nov/2020
65.6%
Department
Implemented/
Implementation
in Progress
Not Implement/
Not yet start
implementation/
No update
HR & GA 7 15
Accounts &
Finance
57 7
HSE 20 12
QA 6 4
Logistics 10 3
Facility 22 22
Production 1
Total Proposal 122 64
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
PR
FAC
LOG
HSE
QA
HR
ACC
PR FAC LOG HSE QA HR ACC
COMPLETED/IN PROGRESS -
√
18 49 10 5 15 5
COMPLETED/IN PROGRESS -
∆
4 8 1 5 2
UNIMPLEMENT/NO UPDATE
- X
22 7 3 4 1 12 15
IMPLEMENTATION STATUS