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5S Kaizen PokaYoke
Presented By: TEAM MASSOC
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)
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.
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.
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
KAIZEN
KAI : Change ZEN : Better Changes for better or Continuous Improvement Masaaki Imai Developer of Kaizen
A Japanese word for the philosophy, that defines managements 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.
Kaizen Objective
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
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.
Implement Solution
Implement solution and control output is effective (i.e. Errors are prevented and/or detected)
Examples of POKA-YOKE
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.
ARIGATO!