KAIZE

N
KAIZEN
Is a Japanese word which
means…
- Change for better.

- quest for continuous improvement.

 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.
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.
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
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)
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,
orderly and well-organized.
 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
3rd Rate Workplace
People leave trash,
…no one
picks it up.
2nd Rate Workplace
People leave trash,
…but others pick
it up.
1st Rate Workplace
No one leave trash,
…but people would pick it up
if they see it.
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
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.
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.
5S
PHILOSOPHY
v Productivity comes from the
elimination of waste
v It is necessary to attack the root
cause of a problem, not just the
symptoms
v Participation of everybody is
required
 5S defined…
Action
Meaning in
5S Original
English Identifying and eliminating
Japanese
all unnecessary items.
1S Sort
Seiri
Arranging necessary items in
good order and easy access.
2S Systematize/
Seiton
Set Cleaning workplace
3S Seiso thoroughly.
Sweep/Shine
4S Seiketsu
Maintaining high standards
Sanitize/ of housekeeping and
Standardize workplace organization at all
5S times.
Shitsuke Sustain/
Creating a culture wherein all
Self-Discipline
members practice the above
4S as a way of life.
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.
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
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.
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.
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.
 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
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
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
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
 Place as close
Things used constantly
as possible

Things Place a little

Things used occasionally
needed further away

Seldom used, Enclose in a separat

but still needed designated place
Classification

No potential use Immediate disposal

Things
Potentially useful Consider where
not
or valuable useful and move
needed

Arrange responsible
Requiring special disposal
inexpensive disposa
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.
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.
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.
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
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
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.
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
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-
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
SEIKETSU PRACTICES

 Visual control signs

 Color coding
 Maintenance labels
 Fixed-point
photography
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.
 Safety Helmet
Head Lamp

SELF-DISCIPLINE

(SHITSUKE)

Train people to follow good

housekeeping rules Clean Uniform

autonomously.
(SHITSUKE…)
• Enhance autonomous management
activities
• Maintain the discipline needed to do a
good job
• Upgrade productivity and quality
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
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
 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:
“GOOD, BETTER, BEST
NEVER LET IT REST
TILL THE GOOD IS
BETTER
AND THE BETTER IS
BEST”
 Thank
You!

Yeken
Open Forum