Shigeo Shingo the Founder of Toyota Production System advised: “By Organizing the Work Place Vital Savings of different types are achieved: Process Time, Material, Space for Work & Human Efforts! While Adding Value at Work: Old Habits Continue & People Stay Put with Un or Dis – Organized Work Place in various Departments in Manufacturing, Offices, Ware Houses & Trading Companies & consequently “Losses” as described above continue! The Processor feels frustrated & is unable to produce in Right Time!
Core Concepts of “5 S” are:
Search Wastes noted above. Next implement: Shining Cleaning, Sorting with Meaning, Systematically Organize All Inputs, Standardize Everything, Work with Self Discipline & Ensure Safety at Work
Balance Work & Habits
Ensure balanced Vertical & Horizontal Team Work
Things will take care on their Own” does not help, “5 S” for organizing Gemba” helps
Value Adding Work happens smoothly only through Systematic Designated Methods
Improve: Styles of Placement of All Materials, Equipment, Cleanliness & Old Habits.
To realize gains by using “5 S”: Audit Before & After Conditions > Adopt Customized Standard Work Styles, Collaborate Vertically, Horizontally & Cross functionally in Departments such as: Sales, R.M. & F.G. Stores, Training, HRD, Operations, Maintenance & Q. A. for achieving Savings as above. Productivity & Efficiency Improvement & Staff Satisfaction.
Define & Place only the Required Material through Regular Sorting
Scrupulously maintain Shining Clean condition at Work Place
Sequentially arrange All the Material & Equipments in Systematic Manner
Design & Sustain the Standards for above 3 aspects
Perform all work with Self Discipline
Ensure: Safe Methods lead to Safe Conditions
Document all Standards & Methods to Sustain Value Adding Culture
Regularly Audit the Past Conditions & Improvements from time to time
Introduction: Kaizen through 4 W’S & 1’H
Uses, Benefits of Kaizen
It is Practiced Globally
Listing of Real Issues & Challenges
Concept Clarity of Gemba, Muda, Mura, & Muri at Work & Personal Life through Tracking & Recording System
Real Cases & Photos of Before & After Implementation of Kaizen
Real Data: Saving of Material, Time, Space, Human Efforts, Analyzing & Needs of Doing
How to Apply Kaizen at Personal Life & Work Stations
Consequences of Not Applying Kaizen, Feedback from Internal Processors
Preparing Diagrams of Material Storage &
Recording: Receipt to Q.A. Checking to
Manufacturing to Storage to Scrapping to
Supply for Acceptance by Customer.
Apply Kaizen for Continual Improvements
Kaizen Workshop Reports, Reviewer’s
Checklist & Simulated Case Working
Group Working for Applying Kaizen at
Work Process & Personal Life
Setting Up & Identification of Tracking System for
improving Productivity & Efficiency.
Understand: How to apply Kaizen at Manufacturing, Offices or Ware Houses, Personal Life and Validation through Real Time Cases
Design & Setting Up of Control Plans, Auditing & Reporting, Acceptance
Criteria for Continual Improvement
through Kaizen & Documentation
Drafting Lessons Learnt during this Training, Preparing Group & Personal Action Plan
The Way Forward in Standardizing & Sustaining Prevention of Deviations
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