5s poka yoke kaizen

8/12/2019 5S Poka Yoke Kaizen

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Business Structures and Processes

Presentation

5SKaizen

PokaYoke

Presented By:

TEAM MASSOC


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What is 5S?

A workplace organization methodology that uses

a list of five Japanese words which are Seiri,

Seiton, Seiso, Seiketsuand Shitsuke.

Sorting(Seiri) Straightening(Seiton)

Systematic cleaning(Seiso)

Standardizing(Seiketsu)

Sustaining(Shitsuke)


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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.


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Sorting (Seiri) (Contd.)


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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.


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Straightening or Setting in

Order/Stabilize (Seiton) (Contd.)


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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 worknot an occasional activity

initiated when things get too messy.


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Shining or Systematic Cleaning (Seiso)

(Contd.)


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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.


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Standardizing (Seiketsu) (Contd.)


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Sustaining the Discipline or

Self-Discipline (Shitsuke)

Maintain and review standards.

Maintain self-discipline in work area.


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Benefits of 5S

Improves organizational efficiency

Reduces waste in all forms

Cuts down employee frustration when the

system doesnt work Improves speed and quality of work

performance

Improves safety Creates a visually attractive environment

Punctuality, commitment & discipline


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KAIZEN

KAI : Change ZEN : Better

Changes for better orContinuous Improvement

Masaaki ImaiDeveloper of Kaizen

A Japanese word for the philosophy, that defines

managements role in continuously encouraging &implementing small improvement involvingeveryone.

Makes the process more efficient , effective andadaptable.

Focuses on simplification of complex process bybreaking them down into their sub-process andthen improving them.


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Kaizen Objective


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POKA-YOKE

POKA : Mistake YOKE : Proofing

A poka-yoke is any mechanism in a leanmanufacturing process that helps an equipmentoperator avoid (yokeru) mistakes (poka).

Its purpose is to eliminate product defects bypreventing, correcting, or drawing attention tohuman errors as they occur.

The concept was formalized, and the termadopted, by Shigeo Shingo (Japanese industrialengineer)as part of the Toyota Production System


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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 milderpoka-yoke.

This tool can be applied to any process, be it inmanufacturing or the service industry.


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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 preventedand/or detected)


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Examples of POKA-YOKE

3.5 inch diskettescannot be insertedunless diskette isoriented correctly.

Circuit breakersprevent electricaloverloads and the firesthat result. When the

load becomes toogreat, the circuit isbroken

The sink is fitted withlight sensors. Thesesensors ensure thatthe water is turned off

in the sink.


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5s poka yoke kaizen

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