5S, Kaizen, PokaYoke

Brief description of Kaizen (Continuous Improvement), PokaYoke (Fool Proofing) and 5S.

1. Business Structures and Processes Presentation 5S Kaizen PokaYoke Presented By: TEAM MASSOC

2. What is 5S? A workplace organization methodology that uses a list of five Japanese words which are  Seiri, Seiton, Seiso, Seiketsu  and  Shitsuke. Sorting (Seiri) Straightening (Seiton) Systematic cleaning (Seiso) Standardizing (Seiketsu) Sustaining (Shitsuke )

3. Sorting (Seiri) Eliminate all unnecessary tools, parts, and instructions. Keep only essential items and eliminate what is not required Prioritizing things per requirements and keeping them in easily-accessible places. Everything else is stored or discarded.

4. Sorting ( Seiri ) (Contd.)

5. Straightening or Setting in Order/Stabilize ( Seiton ) There should be a place for everything and everything should be in its place. The place for each item should be clearly labelled or demarcated. Items should be arranged in a manner that promotes efficient work flow, with equipment used most often being the most easily accessible .

6. Straightening or Setting in Order/Stabilize ( Seiton ) (Contd.)

7. Shining or Systematic Cleaning ( Seiso ) Clean the workspace and all equipment, and keep it clean, tidy and organized. At the end of each shift, clean the work area and be sure everything is restored to its place. Maintaining cleanliness should be part of the daily work – not an occasional activity initiated when things get too messy .

8. Shining or Systematic Cleaning ( Seiso ) (Contd.)

9. Standardizing ( Seiketsu ) All work stations for a particular job should be identical. All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station .

10. Standardizing ( Seiketsu ) (Contd.)

11. Sustaining the Discipline or Self-Discipline ( Shitsuke ) Maintain and review standards. Maintain self-discipline in work area .

12. Benefits of 5S Improves organizational efficiency Reduces waste in all forms Cuts down employee frustration when the system doesn’t work Improves speed and quality of work performance Improves safety Creates a visually attractive environment Punctuality, commitment & discipline

13. KAIZEN ‘KAI’ : Change ‘ZEN’ : Better ‘Changes for better’ or ‘Continuous Improvement’ Masaaki Imai – Developer of Kaizen A Japanese word for the philosophy, that defines management’s role in continuously encouraging & implementing small improvement involving everyone. Makes the process more efficient , effective and adaptable. Focuses on simplification of complex process by breaking them down into their sub-process and then improving them .

14. Kaizen Objective

15. POKA-YOKE ‘POKA’ : Mistake ‘YOKE’ : Proofing A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid ( yokeru ) mistakes ( poka ). Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur. The concept was formalized, and the term adopted, by Shigeo Shingo (Japanese industrial engineer)as part of the Toyota Production System

16. POKA-YOKE (Contd.) It was originally described as baka-yoke , but as this means "fool-proofing" (or "idiot-proofing") the name was changed to the milder poka-yoke . This tool can be applied to any process, be it in manufacturing or the service industry.

17. Poka Yoke - How to use it ? Define the potential mistakes /errors List potential mistakes / errors which could be transferred to the next step in the process. Combine this with other tools (such as brainstorming). Identify Root Causes Investigate and analyse root causes Use other techniques such as 5 Whys for this step Develop ways to prevent errors Brainstorm potential solutions for preventing the error Find ways to make it impossible to do something incorrectly Develop ways to detect errors Brainstorm ideas to detect the error/deviation or mistake early Make it obvious when something has been done incorrectly. E.g. make a system to identify product defects by testing the product's shape, size, color, or other physical attributes Create & test solution Develop solution to prevent or detect errors and test that it is effective Consider characteristics of Poka Yoke solutions: Simple and low cost Part of the process In place where the mistake can occur Does not let the mistake exit the process Implement Solution Implement solution and control output is effective (i.e. Errors are prevented and/or detected)

18. Examples of POKA-YOKE 3.5 inch diskettes cannot be inserted unless diskette is oriented correctly. Circuit breakers prevent electrical overloads and the fires that result. When the load becomes too great, the circuit is broken The sink is fitted with light sensors. These sensors ensure that the water is turned off in the sink.

19. ARIGATO!