5 s
TRANSCRIPT
ALWAYS
CONTINUAL
CHANGE
GOOD
IMPROVEMENT
FOR THE BETTER
KAIZEN: What it is?
1) Process Improvement
2) Observation
3) Use of New Paradigms
4) Short Time
5) Zero Investment
6) Human Development & Empowerment
7) Profits & Savings - Plenty
KAIZEN IS A JOURNEY FROM:
EVENT
RESULT
GROSS
ENFORMENT OF CHANGE
TO CAUSE
TO PROCESS
TO MICRO
TO INDUCEMENT OF CHANGE
KAIZEN IS CONTINUAL IMPROVEMENT
TIMETIMEIM
PRO
VE
ME
NT
IMPR
OV
EM
EN
T
KAIZEN: KNOW THE REALITY THROUGH YOUR SENSE
OBSERVATION INTELLIGENCE
PHYSICAL EFFORT
PARADIGM OF HIGH PRODUCTIVITY & QUALITY
KAIZEN AT GEMBA
GEMBA: PLACE OF WORK
GEMBA is where . . .
Value is added
Actual work is done to meet customer requirement
Problems are solved
Staff is responsible for providing support, not for giving instruction
The ‘S’ Japanese Word What is involved Objective
1SSEIRI
(Sorting Out)
Segregate necessary from unnecessary
Remove what is not required
Decide on frequency of sorting
Saving and recovering Space
2SSEITON
(Systematic Arrangement)
Arranging in order
Place for everything, Everything in its place
Minimizing search time
3SSEISO
(spic and Span)
Cleaning the work place/ equipment
Attaining the warning bell
Inspecting for problems
Taking corrective actions faster
4SSEIKETSU
(Standardization)
Working Methodology
(Procedures & WI)
Achieving higher productivity and better quality
5SSHITSUKE
(Self Discipline)Forming the habit in form of Training and Discipline
Doing it right at First Time
1 ‘S’Seiri
Sort for . . .
Not Needed at All
Needed but not Now
Needed but not here
Needed but not so much Quantity
1 ‘ S’
WANTED UNWANTED
1 ‘S’ – Our respiratory system sorts oxygen and other gases. And exhales other gases which are unwanted for our body
1 ‘ S’ - SEIRI
2 ‘S’
Seiton
Arranging things in systematic way
Example: Jigs & tools
Anybody
Immediately
Can See
Can take out
Can return
Where – Fix the position
What – Fix the item
How Many – Fix the Qty
While fixing the position remember . It should be . . .
Climb Free
Bend Free
Search Free
Count Free
Air Free
FIFO
2 ‘S’ – In our body there is a fixed place for every organ.
2 ‘ S’ - SEITON
STEPS FOR IMPLEMENTATION OF SEIRI & SEITON
MAKE SPOT INSPECTION & ANALYSIS REGARDING UN-NECESSARY
& EXTRA ITEMS
GET RID OF UNNECESSARY THINGS, PROVIDE MINIMUM ADDITIONAL STORAGE FACILITIES
DECIDE WHAT WILL BE STORED WHERE- PLACE FREQUENTLY USED
ITEMS NEARBY AND IN-FREQUENTLY USED ITEMS IN SEPARATE PLACE.
LABEL STORAGE AREAS IN ORDER TO RETURN TO DESIGNATED
LOCATION NUMBER
RECORD STORAGE PLACE IN DIRECTION CHART
REVIEW AND INSPECTION
3 ‘S’
Seiso
KIKEN KITSUI KITENOI
Clean the surroundings !
(DANGER) (PROBLEM) (DIRT)
3 ‘ S’ - SEISO
3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc
Clean Procedure:
Decide what to clean
Decide who is in charge of each cleaning
Decide on cleaning method
Prepare cleaning tools and equipment
Implement cleaning
EXAMPLE : PREPARE CHECKLIST FOR CLEANING
SL.No CHECKLIST TICK
1 Check Floors are clean
2 Check Work areas are clean
3 Check walls are clean
4 Check Pillars and Ceiling are clean
5 Check Windows are clean
6 Check Rooms and Electrical lights are clean
SEISO CYCLE
• BEFORE WORK, CLEAN AND INSPECT THE MACHINERY TOOLS, JIGS & FIXTURES.
• BEGINNING OF WORK - DO TRIALS AND START UP
• DURING OPERATION - CLEAN, INSPECT, DISCOVER AND DEAL WITH ABNORMALITIES
• AFTER COMPLETION OF WORK - DISPOSE OFF AND GET RID OF UN-NECESSARY THINGS
• SEISO IS A PART OF GOOD WORKMANSHIP• SEISO IS AN IMPORTANT PRE-CURSOR WITH
5S
4 ‘S’
Seiketsu
WHAT TO DO STANDARDISATION . . .
Workstation layout,work area layout
Work in progress
Sequence of work
Material & tools used
Machine & their process parameters
Quality parameters, methods of measurement & reporting methods
5 W’s and 1 H
4 ‘S’ – In every human being the structure of fingers are same I.e Standardised. If it is not so, then we call it is
abnormal.
4 ‘ S’ - SEIKETSU
DEMING’S CYCLE
A P
DC
A S
DC
PDCA: Plan – Do – Check – Act
SDCA: Std – Do – Check – Act
A P
DC
A S
DC
A P
DC
A S
DC
A P
DC
A S
DC
TIME
IMP
RO
VE
ME
NT
DEMING’S CYCLE PROCESS
5 ‘S’
Shitsuke
ENSURE . . .
Procedure & Work Instruction are correct.
Standard are expressed in specific.
Visual Aids are used.
Train at all levels.
Work ethics for effective management.
Transparent & Discipline work culture.
5 ‘S’ – Every human body has its standard process which they maintain.
5 ‘ S’ - SHITSUKE
QUOTES
Make effort not an excuse
An error, doesn’t become a mistake until you refuse to correct it.
OTIFEF: On Time In Full Error Free
We don’t employ your hand & legs, we want your head & heart also.
Company is known from the people of company
“Chalak Nahi Malik Bano”