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 and work
to achieve kaizen.
5S – A Housekeeping Techniques and
Strategy
CONCEPTS AND PRINCIPLES:
1.
2.
3.
4.
5.
SEIRE (Sort)
SEITON (Systematize / Stabilize / Straighten)
SEISO (Sweep / Shine)
SEIKETSU (Sanitize / Standardize)
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 wellorganized.
What is 5S?
5S
is a systematized approach to:
 organize work areas
 keep rules and standards
 maintain discipline
5S
utilizes:
 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
Q
C
D
S
M
5S increases PRODUCTIVITY.
5S improves QUALITY.
5S reduces COST.
5S makes DELIVERY on time.
5S improves SAFETY.
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
 Productivity comes from the
elimination of waste
 It is necessary to attack the root cause
of a problem, not just the symptoms
 Participation of everybody is required
5S defined…
Action
5S
1S
2S
3S
4S
5S
Original Meaning in English
Japanese
Identifying and eliminating all
Sort
unnecessary items.
Seiri
Seiton
Systematize/
Set
Arranging necessary items in
good order and easy access.
Seiso
Sweep/Shine
Cleaning workplace thoroughly.
Seiketsu
Sanitize/
Standardize
Maintaining high standards of
housekeeping and workplace
organization at all times.
Shitsuke
Sustain/
Self-Discipline
Creating a culture wherein all
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
or not.
- If no one needs the item after 3 months, it only means
that the item is no longer needed hence, dispose the
item right away.
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.
- Things that are not used often could be places
slightly farther away.
- Make a plan on these principles and locate/store
things accordingly.
Placement of Materials/Equipment Based on
Frequency of Use
PriorityFrequency 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 someOnce a week
where in the office
High
Once a day
Once an hour
Carry or keep at
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
• Decide proper storage layout/classification
• Standardize names
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
Things
needed
Things used constantly
Place as close
as possible
Things used occasionally
Place a little
further away
Seldom used,
but still needed
Enclose in a separate,
designated place
No potential use
Immediate disposal
Potentially useful
or valuable
Consider where
useful and move
Requiring special disposal
Arrange responsible,
inexpensive disposal
Classification
Things
not
needed
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.
Step 4: - Implement cleaning.
Step 5: - Make a daily 5-minute cleaning habit before going
home (Keep it simple and easy to understand.)
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
people’s interest in 5S
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-coding.
Step 2: - Exhibit before and after 5S photos where everyone
will see them.
Step 3: - Recognize good practices and good performance.
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.
Head Lamp
Safety Helmet
SELF-DISCIPLINE
(SHITSUKE)
Train people to follow good
housekeeping rules autonomously.
Clean Uniform
(SHITSUKE…)
• Enhance autonomous management activities
• Maintain the discipline needed to do a good job
• Upgrade productivity and quality consciousness
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:
• Happier employees with high morale.
• Happier customers.
“GOOD, BETTER, BEST
NEVER LET IT REST
TILL THE GOOD IS BETTER
AND THE BETTER IS BEST”
Thank You!
Yekenelle!