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Kaizen InstituteAfrica Asia Pacific

402, Abhishek72, B.M.M. Society

Ellis Bridge Ahmedabad 380006 - IndiaTel: + 91 79- 6588634 / 9562 / 5616

Mobile: (0) 9825073146Email: jmurthy@kaizen-institute.com

www.kaizen-institute.com

Lead By:Jayanth Murthy

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

5sKey to work place improvement

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Putting 5s to WorkWho does not like a

-Clean-Orderly

-Disciplined

Environment ?At home & At work !!!

5s AIMS at achieving this state

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Mess ?!

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Clean & Organized Puts A Smile On Your Face !

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One Way to Do It !!

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The 5s Way To Do It !!

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One to Keep Files !

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The 5s Way To Do It !!

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The 5s Way To Do It !!

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The 5s Way To Do It !!

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The 5s Way To Do It !!

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5-S

Seiri - sort out

Seiton -systematic arrangement

Seiso - Scrub clean, Spic & Span

Seiketsu Standardize - State the rules

Shitsuke - Self-discipline (Follow rules)

KAIZEN and GEMBAKAIZEN are registered trade marks of

KAIZEN INSTITUTE -JAPAN

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1 st Step of 5s

SEIRI Sorting of all items

Segregate Necessary from Unnecessary

Take action on Unnecessary

Step Zero - of 5s

Identify strategic Spots & take Photos / Video To Capture Current Status

Red Tagging & Red Tag Areas (set Rules first) Heaps to Come out 10 trucks (in a factory)

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Red Tag To,

Stock

Facilities

Locations / Space

Documents

Computer Files

Machines

Stationary

Not People !!

When In Doubt,Throw It Out !

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Seiri

Classify into: wanted , ? and unwanted Discard unwanted Create red tag area for ?

items Move ? Items to red tag

area

Put red tag onunmovable ? items

Wanted but not here Wanted but not in this Qty Wanted but not now Not Wanted at all

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

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Before Seiri

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Before Seiri

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Before Seiri

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After Seiri

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2nd Step of 5s

SEITONSystematic ArrangementA Place For Every Thing & Every Thing In Its Place

Arrange Necessary Items Systematically

Easy to identify, find, take & put back Everything to have a place & label

This Leads To Standardizing Of Storage. Any Body Can :- See Things (floor lines, door opening lines, labels etc)- Can Take out it fast (less than 30 sec)- Can Return It- Where, What, How Many ? (Define & label)

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SeitonMake Place for all wanted items Target: Max searching time: 30 seconds

Sign boarding/labeling Outlining Color Coding Visual Controls

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

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Does It Ring A Bell ?

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Before

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Before

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Before

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After Seiton

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After Seiton

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Before

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After Seiton

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After Seiton

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After Seiton

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After Seiton

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The 5s Way To Do It !!

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After Seiton

Af S i

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After Seiton

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After Seiton

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After Seiton

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Before Seiton

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After Seiton

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After Seiton

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After Seiton

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After Seiton

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3rd Step of 5s

SEISOSpic and Span Collective Cleaning

Autonomous Cleaning

Cleaning is Inspection Cleaning with meaning

Seiso Boards (tools)

Seiso calendar & responsibility charts

Decide What, When, Who and How to clean

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Seiso

COT Cleaning with meaning Seiso calendar/map

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

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Cleaning using your own hands

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Cleaning using your own hands

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After Seiton

B f

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Before

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After Seiton

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After Seiton

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Before

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After Seiton

S i B d

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Seiso Board

S i B d

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Seiso Board

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4th Step of 5s

SEIKETSU

Standardization (so that first 3 S is maintained AND

No Unnecessary items pile upNo Mess / out of place itemsNo - Dirt

Make the rules & Follow them SDCA 5 min / 10 min 5s

Setting Standards

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Seiketsu

Setting up of Rules: Place token when tool (or file) is taken Make schedule to restore basic conditions Establish measures to track adherence to

rules answer the 5w1h as regards first 3 S

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

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Token System For Tracing Tools

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Token System For Tracing Tools

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5th Step of 5s

SHITSUKE

Self Discipline

Training & People Involvement

Follow the rules set (if not use ..Retraining / Disciplinary Measures !) Photo Gallery

Slogans

Audit

Radar Charts

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ShitsukeSelf Discipline of adhering to Rules: Adhere to rules yourself Post adherence on visual displays

Spread rules and adherence by teachingothers and tracking everybodys

performance on visual displays

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

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Audit Format

- For Office Environment 5s Audit

- For Production / Factory Environment 5s Audit

- Casting a Radar Chart & Keeping it Updated

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Some More Cases

On5s

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Seiton

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Seiton

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Seiton

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Seiton

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Seiton

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Seiri

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Seiton

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Seiso

S i

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Seiton

S i

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Seiton

What is 5s ?

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Seiri Sorting of all itemsSegregate Necessary from Unnecessary

Take action on Unnecessary

Seiton Systematic Arrangement Arrange Necessary Items SystematicallyEasy to identify, find, take & put backEverything to have a place & label

Seiso Spin & SpanEverything to be cleanUse cleaning as inspection

Seiketsu Setting Standards

Set standards & rules5 min / 10 min 5s Audit

Shitsuke Self DisciplineTraining & People Involvement

5s Requires Team Work

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5s Requires Team Work

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Three More Things

1 Top management Commitment

2 Top management Commitment

3 Top management Commitment

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Founder: Masaaki ImaiHead (Bus. Dev): Bud H. Cox

Africa-Asia-Pacific:

S.Gondhalekar, Mumbai Jayanth Murthy, AfricaS.Durairajan, Chennai ,V.K.Grover, PuneKristianto Jahja , Jakarta

Over 160 consultants worldwide.

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

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Consulting Clients in Africa-Asia Pacific:

Bidco, Nairobi Spinners and Spinners, Kenya Superfoam Ltd, Kenya Taj group of hotels Milton Plastics Bombay Oil Industries

Rallis, India & Hitech Gears (supplier to Honda) Latest additions (from March 2000):

Spencon - Uganda / Zambia / Kenya Comcraft Group Of Companies Power techniques .

KAIZEN and GEMBAKAIZEN are registered trade marks of KAIZEN INSTITUTE -JAPAN

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Unique Features of Consultancy: Hands-on consultants Implementation in shortest time

Cash-stingy solutions Energizing people Release of latent capabilities

Human development Learning organization