Work Improvement Using 5S by sidcalayag

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									                TAIKISHA PHILIPPINES, INC



 5S – A Program
 to Improve Project
 Performance
Venue: TPI Site Office – LSI 3 Project
Date : October 10, 2006
                                         Quality Assurance
                                                         TAIKISHA PHILIPPINES, INC



Objectives
       Improve housekeeping
       Make every individual

                                                                                    3
       responsible for housekeeping
       Productivity improvement by
       saving time, reduced waste,
       space etc.


                                                                       Quality Assurance
      By: Sid Calayag            Version 1: Rev. 0
 QAQC Manager LSI-3 Project   Date: September 25, 2006                                 page 2
                                                         TAIKISHA PHILIPPINES, INC




COMMON MIND SETS…
 Its an additional burden. Too busy to do
 5S activities.
 Why clean it? It will get dirty again
 We cannot change the existing setup.
 More work pressure – No time for these
 things
                                                                                    3
 Expensive – Why to waste money?
 We are comfortable – Why to change?
 It will take time
                                                                       Quality Assurance
      By: Sid Calayag            Version 1: Rev. 0
 QAQC Manager LSI-3 Project   Date: September 25, 2006                                 page 3
                                                        TAIKISHA PHILIPPINES, INC




So,
What’s good in
it?
                                                                                   3
              Before we
              answer . . .
                                                                      Quality Assurance
     By: Sid Calayag            Version 1: Rev. 0
QAQC Manager LSI-3 Project   Date: September 25, 2006                                 page 4
                                                              TAIKISHA PHILIPPINES, INC


                              Why 5S?
Look
Familiar?




                                                                                         3

                                                                            Quality Assurance
      By: Sid Calayag                 Version 1: Rev. 0
 QAQC Manager LSI-3 Project        Date: September 25, 2006                                 page 5
                                                           TAIKISHA PHILIPPINES, INC



So, what’s good in it again?
The winning companies
says…
       Work efficiency enhanced due to organized
       work place
       Achieve remarkable cost reduction in
       construction process and improved
                                                                                      3
       productivity by 20%
       Waste elimination, Cycle time reduction,
       Space generation, Inventory reduction and
       improved work ethics
                                                                         Quality Assurance
        By: Sid Calayag            Version 1: Rev. 0
   QAQC Manager LSI-3 Project   Date: September 25, 2006                                 page 6
                                                                   TAIKISHA PHILIPPINES, INC




                Remove waste
Implement so that ‘waste becomes
visible to facilitate waste removal’
                                                                                              3
         Waste = Current work – money
                               generating work
 From current work remove work that does not generate money

                                                                                 Quality Assurance
       By: Sid Calayag                     Version 1: Rev. 0
  QAQC Manager LSI-3 Project            Date: September 25, 2006                                 page 7
                                                            TAIKISHA PHILIPPINES, INC




                                                                                       3
                        A program to help us
                          improve project
                            performance
                                                                          Quality Assurance
     By: Sid Calayag                Version 1: Rev. 0
QAQC Manager LSI-3 Project       Date: September 25, 2006                                 page 8
        TAIKISHA PHILIPPINES, INC



Let’s begin….




                             Quality Assurance
                                                                  TAIKISHA PHILIPPINES, INC



 Definition of 5S
(1) SEIRI (Sort)
  Distinguishing between necessary and unnecessary things, and getting rid
  of what you do not need
(2) SEITON (Set in Order)
  The practice of orderly storage so the right item can be picked efficiently
  (without waste) at the right time
(3) SEISOU(Shine)
  Create a clean worksite without garbage and dust
                                                                                             3
(4) SEIKETSU(Standardization)
  Standardization of best practices
(5) SHITSUKE (Sustain)
  The practice of developing customs so that the workplace regulations and
  rules are correctly practiced
                                                                                Quality Assurance
        By: Sid Calayag                   Version 1: Rev. 0
   QAQC Manager LSI-3 Project          Date: September 25, 2006                                page 10
                                                                                TAIKISHA PHILIPPINES, INC


Promotion of 5S
    (1)                                (2)                        (3)                    (4)
  SEIRI                             SEITON                   SEISOU                  SEIKETSU
  (Sort)                             (set in                                         (Standard)


                                                                                                              3
Dispose what                         order)                  (Shine)                 Standardized
is not needed                                                                         the solution
                                    Can retrieve             Make the
                                   when required             workplace
                                                               clean



                                              (5)
                                           SHITSUKE
                                             (Discipline)
         Develop customs that allow practice of regulations and rules
                                                                                                 Quality Assurance
           By: Sid Calayag                              Version 1: Rev. 0
      QAQC Manager LSI-3 Project                     Date: September 25, 2006                                   page 11
                                                           TAIKISHA PHILIPPINES, INC




First Module



                                                                                      3
                               (Sort)
                                                                         Quality Assurance
       By: Sid Calayag             Version 1: Rev. 0
  QAQC Manager LSI-3 Project    Date: September 25, 2006                                page 12
                                                                     TAIKISHA PHILIPPINES, INC



SEIRI (Sort) refers to:
   Distinguishing between necessary
  things and unnecessary things and
  getting rid of what you do not need


   Steps
                                                                                                  3
   Stratify                     Dispose                         Assign fixed place


                                                                                     Quality Assurance
        By: Sid Calayag                      Version 1: Rev. 0
   QAQC Manager LSI-3 Project             Date: September 25, 2006                                  page 13
                                                              TAIKISHA PHILIPPINES, INC




‘Stratification’ refers to:
Assorting things around oneself into those
that are required and those that are not
required
                                                                                         3
• Other than things used daily are non-required things
• Quantity in excess of what is used daily is non-required
• ‘Leave only this, just in case’ is strictly prohibited


                                                                            Quality Assurance
          By: Sid Calayag             Version 1: Rev. 0
     QAQC Manager LSI-3 Project    Date: September 25, 2006                                page 14
                                                                       TAIKISHA PHILIPPINES, INC



                         Standards                                      Action

Frequency of Usage                                     Dispose


Things used approximately once in 1 to 6 months        Place in a warehouse faraway



Things used once a week
                                                       Gather together in the store in
                                                       vicinity of work

                                                       Place so that they are easy to pick.
                                                                                                       3
Things used daily
                                                       Make it easy to return. Identifiable

                                                       Place within arm’s length where
Things used every hour
                                                       they can be easily reached



                                                                                          Quality Assurance
            By: Sid Calayag                    Version 1: Rev. 0
       QAQC Manager LSI-3 Project           Date: September 25, 2006                                     page 15
                                                        TAIKISHA PHILIPPINES, INC




                                                                                   3

                                                                      Quality Assurance
     By: Sid Calayag            Version 1: Rev. 0
QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 16
                                                              TAIKISHA PHILIPPINES, INC




Assigning fixed places refers
to:
Preparing rules and making visible ‘where’


                                                                                         3
and in ‘what quantity’’ the required things
are to be placed

• Decide locations for things that will remain
• Make rules for locations
• Making visible refers to visual management
• Start with what can be done
                                                                            Quality Assurance
           By: Sid Calayag            Version 1: Rev. 0
      QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 17
                                                           TAIKISHA PHILIPPINES, INC




Location of things that will remain
  should consider :
(1) Where it will be used
(2) Where it will be placed
                                                                                      3
(3) How much it will be placed
(4) How it will be placed

                                                                         Quality Assurance
        By: Sid Calayag            Version 1: Rev. 0
   QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 18
                                                               TAIKISHA PHILIPPINES, INC



Seiri = Sorting
Seiri = Sorting                 Improvement methods

1.Flow Process Chart (Procedural
  Analysis)


                                                                                          3
  Drawing a process flow chart for the system
  Ex. How to make and use category wise grouping
2.Operational Analysis
  Preparing the sequence of operations for system
  Ex. How to perform Seiri (sorting)
3.Check List
  A check sheet is used to decide what sort of main
    system and sub system are necessary.
                                                                             Quality Assurance
        By: Sid Calayag                Version 1: Rev. 0
   QAQC Manager LSI-3 Project       Date: September 25, 2006                                page 19
                                                                       TAIKISHA PHILIPPINES, INC




SEIRI = Sorting
SEIRI = Sorting
Meaning
Meaning     Distinguish between necessary and unnecessary
            Distinguish between necessary and unnecessary
 items and eliminate the unnecessary items
  items and eliminate the unnecessary items

  Activity                      Establish a criteria for eliminating unwanted items
                                Eliminate unwanted items either by disposing
                                                                                                  3
                                them or by relocating them.


  Success                       Area saved or percentage of space available
  Indicator
                                                                                     Quality Assurance
        By: Sid Calayag                        Version 1: Rev. 0
   QAQC Manager LSI-3 Project               Date: September 25, 2006                                page 20
isc1

                                                                       TAIKISHA PHILIPPINES, INC




       INTERACTIVE BIT

                                Give me three examples
                                of areas that could benefit
                                from sorting                                                      3

                                                                                     Quality Assurance
              By: Sid Calayag                  Version 1: Rev. 0
         QAQC Manager LSI-3 Project         Date: September 25, 2006                                page 21
Slide 21

isc1       ntil here, we can conclude the first ,module of the presentation.
           Sid Calayag, 10/9/2006
                                                          TAIKISHA PHILIPPINES, INC




Second Module



                                                                                     3
                (Set in order)
                                                                        Quality Assurance
       By: Sid Calayag            Version 1: Rev. 0
  QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 22
                                                           TAIKISHA PHILIPPINES, INC




SEITON (Set in order) refers to :
Implementing functional storage by deciding
correct placement method and layout so that

                                                                                      3
the required objects can be quickly used
what it is required


         Steps

 Assign fixed places and
      fixed quantity
                                          Make it compact
                                                                         Quality Assurance
        By: Sid Calayag            Version 1: Rev. 0
   QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 23
                                                             TAIKISHA PHILIPPINES, INC



Assigning fixed places and
fixed quantity :
Refers to facilitating picking and placing and
ensuring zero shortages
• Give priority to use frequency and decide fixed place
• Consider also safety (mainly weight)
                                                                                        3
    • Place heavy objects at a height where they are easy to pick
      from
• Eliminate labor required for searching and returning

• Decide placing volume bused on usage volume (1 time, 1 day)
                                                                           Quality Assurance
          By: Sid Calayag            Version 1: Rev. 0
     QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 24
                                                                           TAIKISHA PHILIPPINES, INC


Decision standards for fixed positions
(1)    Where it will be used                    Clarification of usage objective and place


                                                Near where it will be used so that work can be done
(2)    Where it will be placed
                                                while walking. Stand-up operations


(3)    How much will be placed                  Maximum, Minimum, Order point




                                                                                                               3
                                                Easy to place, Easy to remove (one-touch
(4)    How will it be placed
                                                operation)


(5)    Indication of placing location           Coloring, boundaries


                                                Illustrative indication, component name indication,
(6)    Recognize visually
                                                Quantity indication

                                                First in- First out, Recognize by observing
(7)    Stagnating time is visible
                                                placement date


(8)    Decide person in-charge of supervision   Indicate person responsible


                                                                                                  Quality Assurance
           By: Sid Calayag                         Version 1: Rev. 0
      QAQC Manager LSI-3 Project                Date: September 25, 2006                                         page 25
                                                            TAIKISHA PHILIPPINES, INC



Seiton = Systematic Arrangement
Seiton = Systematic Arrangement

How to achieve Systematic
  Arrangement ?

•   Decide where things belong                                                         3
•   Decide how things should be put away

•   Obey the Put away rules

                                                                          Quality Assurance
         By: Sid Calayag            Version 1: Rev. 0
    QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 26
                                                            TAIKISHA PHILIPPINES, INC



Seiton = Systematic Arrangement
Seiton = Systematic Arrangement
How to achieve Systematic Arrangement ?

•   Decide where things belong
    • Standardize Nomenclature


                                                                                       3
    • Determine an analytical method of storage

•   Decide how things should be put away
    • Name & locations to everything. Label both item and
      location
    • Store material functionally
    • Prevent mistakes with coding by shapes & color
                                                              contd..

                                                                          Quality Assurance
         By: Sid Calayag            Version 1: Rev. 0
    QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 27
                                                           TAIKISHA PHILIPPINES, INC


Seiton = Systematic Arrangement
Seiton = Systematic Arrangement
How to achieve Systematic
Arrangement ?

• Decide how things should be put away
  • Follow first in first out rule
  • If two identical items are to be located, then store
    them separately, color code them.
                                                                                      3
• Obey the rules
  • Put the things back to their location after
    their use

                                                                         Quality Assurance
        By: Sid Calayag            Version 1: Rev. 0
   QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 28
                                                        TAIKISHA PHILIPPINES, INC

Examples of tools arrangement
          (Seiton)



                                                                                   3

                                                                      Quality Assurance
     By: Sid Calayag            Version 1: Rev. 0
QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 29
                                                            TAIKISHA PHILIPPINES, INC




SEITON = Systematic Arrangement
SEITON = Systematic Arrangement
The main target areas for Seri-Seiton improvement are ::
The main target areas for Seri-Seiton improvement are


                                                                                       3
   Tool-setting and preparation operations,
    Tool-setting and preparation operations,
   line balancing and process planning,
    line balancing and process planning,
   peak time problems etc.
    peak time problems etc.

Improvement Methods
 Improvement Methods
   Kit Method // Assembly box method //Outside tool setting
    Kit Method Assembly box method Outside tool setting
   Cassettisation //Parallel operations //Changes in
    Cassettisation Parallel operations Changes in
   assignment method
    assignment method
                                                                          Quality Assurance
         By: Sid Calayag            Version 1: Rev. 0
    QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 30
                                                                       TAIKISHA PHILIPPINES, INC




SEITON = Systematic Arrangement
SEITON = Systematic Arrangement

   Meaning
   Meaning          To determine type of storage and layout
                    To determine type of storage and layout
 that will ensure easy accessibility for everyone ..

                                                                                                  3
  that will ensure easy accessibility for everyone
  Activity                      - Functional storage
                                - Creating place for everything and putting
                                  everything in its place

  Success - Time saved in searching
  Indicator - Time saved in material handling
                                                                                     Quality Assurance
        By: Sid Calayag                        Version 1: Rev. 0
   QAQC Manager LSI-3 Project               Date: September 25, 2006                                page 31
isc4

                                                                      TAIKISHA PHILIPPINES, INC




       INTERACTIVE BIT

                                Give me three examples
                                of areas that could benefit
                                from systematic arrangement/                                     3

                                                                                    Quality Assurance
              By: Sid Calayag                 Version 1: Rev. 0
         QAQC Manager LSI-3 Project        Date: September 25, 2006                                page 32
Slide 32

isc4       This wiull conclude the second module of the presentation.
           Sid Calayag, 10/9/2006
                                                          TAIKISHA PHILIPPINES, INC




Third Module



                                                                                     3
               (Shine-Clean)
                                                                        Quality Assurance
       By: Sid Calayag            Version 1: Rev. 0
  QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 33
                                                            TAIKISHA PHILIPPINES, INC




SEISO (Shine, cleaning) refers to :
Removal of dirt and by investigating source
of dirt preparing countermeasures


        Steps
                                                                                       3
                                             Take action to prevent
 Identify source of occurrence               dirtiness and its
                                             occurrence
                                                                          Quality Assurance
        By: Sid Calayag             Version 1: Rev. 0
   QAQC Manager LSI-3 Project    Date: September 25, 2006                                page 34
                                                            TAIKISHA PHILIPPINES, INC




Actions to prevent dirtiness and its
occurrence refers to:
countermeasures against source of occurrence
include countermeasures (challenge towards
common sense) for process methods (defects in
processing conditions etc.)                                                            3
• The basic point is sweeping, cleaning and inspecting
• It is also important to take immediate actions such as placing a
  cover etc.
• Accumulation of small points will lead to a situation where
  sweeping is not required
                                                                          Quality Assurance
         By: Sid Calayag            Version 1: Rev. 0
    QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 35
                                                                    TAIKISHA PHILIPPINES, INC




SEISO – SHINE - CLEANING
SEISO – SHINE - CLEANING
Meaning
Meaning     Cleaning trash, filth, dust and other foreign
            Cleaning trash, filth, dust and other foreign
 matter. Cleaning as a form of Inspection.
 matter. Cleaning as a form of Inspection.
  Activity                     - Keep workplace spotlessly clean
                               - Inspection while cleaning
                               - Finding minor problems with cleaning
                                                                                               3
                                 inspection

 Success                       - Reduction in machine down time
 Indicator                     - Reduction in no. of accidents
                                                                                  Quality Assurance
       By: Sid Calayag                      Version 1: Rev. 0
  QAQC Manager LSI-3 Project             Date: September 25, 2006                                page 36
isc5

                                                                       TAIKISHA PHILIPPINES, INC




       INTERACTIVE BIT

                                Give me three examples
                                of areas that could benefit
                                from cleaning.                                                    3

                                                                                     Quality Assurance
              By: Sid Calayag                  Version 1: Rev. 0
         QAQC Manager LSI-3 Project         Date: September 25, 2006                                page 37
Slide 37

isc5       ntil here, we can conclude the first ,module of the presentation.
           Sid Calayag, 10/9/2006
                                                            TAIKISHA PHILIPPINES, INC




SEIKETSU (Standardization )
refers to:
Standardization of 5S through ‘visual
management’

         Steps
                                                                                       3
      Grasp vital points for         Make abnormalities visible in
         management                  management points


                                                                          Quality Assurance
         By: Sid Calayag            Version 1: Rev. 0
    QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 38
                                                                           TAIKISHA PHILIPPINES, INC


      Standardization of 5S
               Clarification of vital points for management
                     - What are the minute defects
                     - Basic conditions: Cleanliness, refueling, replace tightly bind
(1)
                       fast, dirt, looseness
                     - Operating conditions: lighting, temperature, time, weight,




                                                                                                      3
                       Equipment, jigs and tools, sub-materials


              Prepare standards for the conditions
                 -        Objectivity of judgment standards for normal versus
(2)
                          abnormal
                 -        Judgment without using measurement, knowledge, intuition
                          and knack

              Judgment standards for abnormalities
(3)              -        Inspection methods that can be used by anybody
                 -        Methods for actions against abnormalities
                                                                                         Quality Assurance
           By: Sid Calayag                         Version 1: Rev. 0
      QAQC Manager LSI-3 Project                Date: September 25, 2006                                page 39
                                                               TAIKISHA PHILIPPINES, INC


 Points for Visual Management
(1)    Recognize well even from a distance


(2)    There are indicators on items to be managed


(3)


(4)
       Whether good or bad is clear, and anybody can point out


       Anybody can use, and convenient if used
                                                                                          3
(5)    Anybody can follow and repair quickly


(6)    Use of tools leads to neatness

                                                                             Quality Assurance
           By: Sid Calayag             Version 1: Rev. 0
      QAQC Manager LSI-3 Project    Date: September 25, 2006                                page 40
                                                         TAIKISHA PHILIPPINES, INC



SEIKETSU - STANDARDIZING
 Regularizing 5S activities by putting
 systems in place – Everyone does things
 the same way
 Make it easy for everyone to identify the
 state of normal or abnormal condition.
 For maintaining previous 3S, use visual
                                                                                    3
 management
      5S IS EASY TO DO ONCE –
     CONSISTENCY IS DIFFICULT
                                                                       Quality Assurance
      By: Sid Calayag            Version 1: Rev. 0
 QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 41
                                                                        TAIKISHA PHILIPPINES, INC




SEIKETSU - STANDARDIZING
SEIKETSU - STANDARDIZING
Meaning
Meaning                         Setting up standards //Norms for a neat, clean,
                                Setting up standards Norms for a neat, clean,
                                workplace and details of how to maintain the
                                workplace and details of how to maintain the


                                                                                                   3
                                norm (Procedure)
                                norm (Procedure)

Activity                         - Innovative visual management
                                 - Color coding
                                 - Early detection of problem and early action

Success                         - Increase in 5S indicator
Indicator
                                                                                      Quality Assurance
        By: Sid Calayag                         Version 1: Rev. 0
   QAQC Manager LSI-3 Project                Date: September 25, 2006                                page 42
                                                         TAIKISHA PHILIPPINES, INC




INTERACTIVE BIT


      Give example of how to
      make the practice become
      standard.
                                                                                    3

                                                                       Quality Assurance
      By: Sid Calayag            Version 1: Rev. 0
 QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 43
                                                            TAIKISHA PHILIPPINES, INC




SHITSUKE (Sustain ) refers to:
Preparation of workplace atmosphere
where visual management is properly
observed

         Steps
                                                                                       3
 Check state of                  Innovate to ensure
 observance of                   observance
 standardization of 5S
                                                                          Quality Assurance
         By: Sid Calayag            Version 1: Rev. 0
    QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 44
                                                         TAIKISHA PHILIPPINES, INC



SHITSUKE – SUSTAIN – SELF
DISCIPLINE & TRAINING

 Make ‘5S’ is a HABIT
 Without this, the time involved in                                                 3
 all the other S will be in vain.


                                                                       Quality Assurance
      By: Sid Calayag            Version 1: Rev. 0
 QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 45
                                                          TAIKISHA PHILIPPINES, INC



Shitsuke = Self Discipline
Shitsuke = Self Discipline
We need everyone to maintain
5S guidelines.

To maintain DISCIPLINE, we
need to practice and repeat
                                                                                     3
until it becomes a way of life.

Discipline is the Core of 5S
                                                                        Quality Assurance
       By: Sid Calayag            Version 1: Rev. 0
  QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 46
                                                        TAIKISHA PHILIPPINES, INC




SHITSUKE – SUSTAIN – SELF
DISCIPLINE & TRAINING


                                                                                   3
     Commitment
     + Everyone’s Involvement
     = Success to 5S

                                                                      Quality Assurance
     By: Sid Calayag            Version 1: Rev. 0
QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 47
                                                                        TAIKISHA PHILIPPINES, INC




SHITSUKE - SUSTAIN
SHITSUKE - SUSTAIN
Meaning Every one sticks to the rule and
Meaning Every one sticks to the rule and
 makes it a habit
 makes it a habit
 Activity - Participation of everyone in developing good
                                  habits
                                - Regular audits and aiming for higher level
                                                                                                   3
  Success                        - High employee morale

  Indicator                      - Involvement of all people
                                                                                      Quality Assurance
        By: Sid Calayag                         Version 1: Rev. 0
   QAQC Manager LSI-3 Project                Date: September 25, 2006                                page 48
                                                          TAIKISHA PHILIPPINES, INC




The rules…
       Remove fixed ideas.
       Think of ways to make it possible.


                                                                                     3
       No excuses needed.
       Go for the simple solution, not the perfect one.
       Correct mistakes right away.
       Repeat ‘Why’ 5 times.
       Ask ideas from many people.
       There is no end to improvement.

                                                                        Quality Assurance
       By: Sid Calayag            Version 1: Rev. 0
  QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 49
                                                              TAIKISHA PHILIPPINES, INC




The benefits . . .
           Reduced set-up times
           Reduce searching time



                                                                                         3
           Increased floor space
           Lower safety incident/accident rate
           Less wasted labor
           Higher Quality
           Lower cost
           Reliable Delivery


                                                                            Quality Assurance
      By: Sid Calayag                 Version 1: Rev. 0
 QAQC Manager LSI-3 Project        Date: September 25, 2006                                page 50
                                                                                         TAIKISHA PHILIPPINES, INC


                           Elimination of Waste
   5 S Element                        Waste/ Improvement Item                          Deliverable


Sorting-Visual                    Elimination of finding.                              Reduced Costs
                                  Elimination of nonconformances.                      Increased Safety
Placement                         Elimination of motion.                               Improved Quality
                                  Reduction of part selection errors.                  Increased Product Options.



Systematic
Organization

Scrubbing Clean
                                  Elimination of finding.
                                  Reduction of part selection errors.


                                  Increased safety.
                                                                                       Reduced Costs
                                                                                       Improved Quality
                                                                                       Increased Product Options

                                                                                       Increased Safety
                                                                                                                                 3
                                  Preventive maintenance.                              Improved Quality
                                  Increased equipment knowledge.


Standardization                   Increased equipment life.                            Improved Quality
                                  Higher morale.                                       Consistent Delivery
Control                           Clean environment.                                   Improved Safety
                                  Increased visibility of nonconformances.

                                                                                                                    Quality Assurance
          By: Sid Calayag                                      Version 1: Rev. 0
     QAQC Manager LSI-3 Project                             Date: September 25, 2006                                               page 51
                                                                                         TAIKISHA PHILIPPINES, INC

                5S
           Implementation
                Plan

      Step 1                        Step 2                Step 3
                                                                                        Step 4
                                                                                                           Step 5
   Establish 5 S            Develop Specific      Develop Communication
                                                                            Develop 5 S Training Plan
Implementation Team       Implementation Plan               Plan                                        Implement 5 S




         Systematic
        Organization
                                                   Progressive
                                                 Enhancement
                                                      s
                                                                                                     Standardization                3
                                                                                                 Cleanliness
        Visual Placement



                                                           Step 6
                                                Verification of Effectiveness


                                                                                                                       Quality Assurance
            By: Sid Calayag                                     Version 1: Rev. 0
       QAQC Manager LSI-3 Project                            Date: September 25, 2006                                                 page 52
                                                            TAIKISHA PHILIPPINES, INC




                              5S Audit


Conduct an audit
to measure                                                                             3
improvement



                                                                          Quality Assurance
      By: Sid Calayag               Version 1: Rev. 0
 QAQC Manager LSI-3 Project      Date: September 25, 2006                                page 53
                                                          TAIKISHA PHILIPPINES, INC




Roles and Responsibility
  Leaders must set the tone and lead by
  example.


                                                                                     3
  We should commit to the initiative, Provide
  time to the workforce to develop and
  implement 5S changes.
  Any implementation should have a drive.
  Conduct short, focused and frequent
  communication sessions.
  Share the successes


                                                                        Quality Assurance
       By: Sid Calayag            Version 1: Rev. 0
  QAQC Manager LSI-3 Project   Date: September 25, 2006                                page 54
                                                                   TAIKISHA PHILIPPINES, INC


Expanding the Strategy
                              Performance Excellence

 6 Sigma                                                         Kaizen
 • Disciplined Methodology                                       • Philosophical Approach



                                                                                                  3
 • Technical Approach                                            • Common Sense Approach
      (Quantitative)                                                  (Qualitative)
 • Data Driven - Statistical                                     • Data Driven - Observation
 • Customer Focus                                                • Operational Focus
 • Reduce Variation                                              • Waste Elimination 5S
 • Focus on Large Impact                                         • Incremental Change
 • Larger/Longer Projects                                        • Smaller/Shorter Projects

 Complimentary Tools Driving Continuous Improvement
 Complimentary Tools Driving Continuous Improvement
                                                                                     Quality Assurance
      By: Sid Calayag                    Version 1: Rev. 0
 QAQC Manager LSI-3 Project           Date: September 25, 2006                                      page 55
                                                                                    TAIKISHA PHILIPPINES, INC

 Comparative Analysis
                      6s                     Improvement Methodologies                                  Kaizen/Lean
Measure
                                             • Similar in Structure                      Evaluate
- Data Collection
- Determine Process Potential / Goals        • Improvements measured against             - Baseline Process Performance
                                             established process                         - Establish Target
Evaluate                                     • Team oriented                             Decide
- Root Cause / Vital Few
                                                                                         -Compare solutions
- Statistical Analysis
                                                                                         - Choose
Improve & Verify                             • Similar improvement tools
                                             • Measure effectiveness of improvements     Act
- Implement Improvement




                                                                                                                                  3
                                                                                         -Communicate
- Validate Improvement                       • Maintain new performance level            - Implement improvement
                                             • Standardize & Proceduralize               - Control
Standardize
- Standardize / Leverage
                                                                                         Measure
- SPC
                                             Results                                     - Validate improvement
- Update Procedures
                                                                                         - Standardize
                                             • More Efficient Processes
                                                                                         - Update Procedures
 Focus
 - Reduce Process Variation                                                              Focus
                                                                                         - Eliminate Waste 5S
 - Identify Critical Cause and Focus         Comparison
 Resources for Maximum Impact                                                            - Seek Incremental Process Changes
                                             • Both are Effective Improvement
                                             Mechanisms                                  Summary
 Summary
 - Technical Approach based on Statistical
                                             • CPI/6s best applied to large complex      - Common Sense Approach based on
                                             problems                                    Observation
 Analysis
                                                                                         - Applicable to all types of processes
 - Requires Significant Data Collection      • Kaizen/Lean best applied to achieve
                                                                                         - Defined improvement strategy
 - Best applied to Manufacturing Processes   incremental changes and eliminate wastes.   - Typical Projects 1 week
 - Typical Projects 1-3 Months


                                                                                                              Quality Assurance
             By: Sid Calayag                                Version 1: Rev. 0
        QAQC Manager LSI-3 Project                       Date: September 25, 2006                                            page 56
        TAIKISHA PHILIPPINES, INC




Countdown begins now….




                             Quality Assurance

								
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