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

16. 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

17. 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.

18. 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)

19. 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.

20. ARIGATO!