Improvements

Kaizen
(Small improvements) or

Innovations
(Dramatic Improvement as a results of a large investment)

KAIZEN
INCREMENTAL BUT CONTINUOUS PROGRESS

INNOVATION

DRAMATIC BUT

INTERMITTENT
PROGRESS

THE IDEAL

HIGHER STANDARD ACHIEVED THROUGH INNOVATION IS SUBJECT TO DETERIORATION UNLESS CONTINUING EFFORTS ARE MADE FIRST TO MAINTAIN IT AND THEN TO IMPROVE IT

KAIZEN

PLUS

INNOVATION

DESIRABLE PROGRESS BY COMBINATION OF TWO OPPOSING APPROACHES

MAINTENANCE

INNOVATION

KAIZEN
MAINTENANCE

INNOVATION

Various Kaizen Programs Integrated into the Workplace

5S KSS

Seiri, Seiton, Seiso, Seiketsu, Shitsuke Kaizen Suggestion System QC Circle Total Quality Control Total Productive Maintenance Just-In-Time Production

QCC
TQC TPM

JIT

TPM

Overlapping Areas between Kaizen Programs

TQC
JIT
Toward Excellence

QCC

5S

KSS

PARTICIPATIVE MANAGEMENT

A Suggested Sequence of Implementing Kaizen Programs

QCC

TQC

TPM

JIT

KSS
Start Here

5S

Super 5S is a Company-wide Participation Program for Kaizen

Super 5S is a company-wide participation program involving everyone in the organization. It is a very effective approach for motivating people, and improving productivity and the work environment .

Four Major Objectives of a Super 5S Program

Developing Kaizen-minded people at workplace. Building good teamwork through participation. Developing managers and supervisors for practical leadership. Improving infrastructures for introduction of advanced Kaizen technologies.

The Origin of The Term 5S

5S is a set of five Japanese words. Each word starts with a sound of se or shi.
They are Se-i-ri, Se-i-to-n, Sei-so, Se-i-ke-tsu, and Shi-tsuke.

5S PRACTICE IN DETAIL
Throw away / return things which are not needed Develop a Central Unwanted item Store Needed things stored: low, medium & high usage; and Treat defects, leakage, breakage, and their causes.

The Definition of Seiri

Seiri Seiton

Shitsuke

Seiketsu

Seiso

Seiri(Sorting and Clearing)

is the sorting out and discarding of unnecessary items in the workplace.

The Definition of Seiton

Seiri Seiton

Shitsuke

Seiketsu

Seiso

Seiton(Organizing orderliness)
is the arrangement of necessary items into good order so that they can be easily selected for use.

The Definition of Seiso

Seiri Seiton

Shitsuke

Seiketsu

Seiso

Seiso(Cleaning with meaning)

is cleaning up ones workplace completely so that there is no dust on floors, machines or equipment.

The Definition of Seiketsu

Seiri Seiton

Shitsuke

Seiketsu

Seiso

Seiketsu(Standardization)
is maintaining ones workplace so that it is productive and comfortable by repeating Seiri Seiton - Seiso.

The Definition of Shitsuke

Seiri Seiton

Shitsuke

Seiketsu

Seiso

Shitsuke(Training and Self discipline)

is training people to follow good work habits and the strict observation of workplace rules.

1 2
3 4

Continued commitment and support by top management Super 5S starts with education and training There are no observers in Super 5S, everyone participates Repeat the 5S cycle in order to achieve a higher standard

PART 3

Step by Step

Implementation of a

SUPER 5S

Program

How to SEIRI Your Workplace

Which ???
Items Not Necessary

Stratification
Items having no value and easy to dispose

Required Action
Throw away immediately

Items having Audit and dispose/auction who some value for sale and needs audit offers the best price
Items having no value but their disposal is costly

Work out a less costly and safe way for disposal Must be placed near the point of use Can be placed farther away Must be stored separately with clear identification

SEIRI
Items frequently used

Items Necessary
For SEITON

Items sometimes used Items not used at all but must be kept

Seiri: Throw away things that are not needed and not being used. Use space more economically
Space

is money

Seiton: Improve locations and methods of storing things so that searching and retrieval time is minimized

Time is money

Seiso: Continue daily cleaning schedule for the creation of a

Healthy and comfortable workplace.

Motivate colleagues to come up

with creative improvements for the workplace.

A 3rd class workplace:

has people who make a mess and no one cleans up.

has people who make a mess and another group of people clean up. has people who dont make a mess and yet everyone cleans up.

A 2nd class workplace:

A 1st class workplace:

BASIC 5 S (Identify Specific Places for different activities)

1. 2. 3. 4. 5. 6. 7. 8. Nurses duty area Reception counter Discharge counter Examination room Emergency bay Sterile bay Emergency tray Clean Linen room 1. 2. 3. 4. 5. 6. 7. 8. Dirty utility room Waste disposal area Stationary rack Registers cupboard Changing room Eating room Duty room Toilet area

How to SEITON Your Workplace

Stratification Required Action

SEITON

Items frequently used

Must be placed near the point of use

Items Necessary

Items sometimes used

Can be placed farther away

SEIRI

Items not used at all but must be kept

Must be stored separately with clear identification

Reserved seats Matching names

SUPER

SEITON

A1
A1

A2
A2

A3
A3

A4
A4

A5
A5

A6
A6

A7
A7

B1
B1

B2
B2

B3
B3

B4
B4

B5
B5

B6
B6

B7
B7

C1

C2

C3

C4

C5

C6

C7

C1

C2

C3

C4

C5

C6

C7

Seven Seiton Principles

1.

Follow the first-in-first-out (FIFO) method for storing items. Assign each item a dedicated location. All items and their locations should be indicated by systematic labeling. Place items so that they are visible to minimize search time. Place items so they can be reached or handled easily. Place frequently used items near the user. Risk identification

2. 3.

4.

5.

How to Seiton

6.

7.

5 S TOOLS
Red Tag Alignment X axis Y axis Theory Numbering Alphabeticl order Ascending order Left to Right order Top to Bottom order Zones Labeling Symbols Street lines Name boards Directions Safety signs Check lists Instructions sheets Colour code

SUPER

SEITON

Transparent / no cover Stock level indicators

B10-100

B12-100

B10-150

B12-150

A Clinical Notes

B Investigation forms

C Observation charts

A1

Admission papers

B1 ECG forms

C1 Fluid Balance charts

A2 Continuation papers

B2 Laboratory Inv.

C2 Kick count chart

A3 Diagnosis cards

B3 X-Ray

C3 Temperature chart

A4 OT Request (Routine)

OT Request (Urgent)

B4 Ultra sound scan request

C4 Partograms

Green (Maximum stock) Orange

(Reorder)
Red (Minimum stock)

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

A3 Diagnosis cards

SUPER

SEITON

1 2 3 4 5 6 7 8 9 101112

Seiri wastes No horizontal piling Nothing on floor

SUPER

SEITON

10

11

12

Retrieval within 30 seconds Labeling reserved seats Color identification

10 11

12

10 11 12