Professional Documents
Culture Documents
Course Outline
Overview of a World Class benchmark A Lean approach to Resource Management 5S as a foundation of Lean Application of 5S in a School setting Kaizen Project Recycling synergizing 5S as a Visual tool
Quality
Cost
Delivery
Continueos Improvement
5S as a foundation of Lean
Goal / Vision
To be the center of excellence, renown internationally for Educational Innovations exceeding expectations of National Standards put forward by the Teacher Training Agency
Methodology Benchmark World Class requirements of creating Value to Customers Adopt a Lean approach based on 5S as a foundation Apply 5S practice in a School setting through Kaizen Project Recycling
Introduction
National Standards put forward by the Teacher Training Agency emphasizes the importance of good resource management within schools. Course Objective
This session provides a Lean approach to development activities to support schools in their own improvement journey.., aims to provide teachers and management an insight of Lean tools adapted to improve teacher and pupil autonomy relate how the benefits of Lean can make an impact on resource management. helps in establishing benchmarks for good practice in a current World Class requirement.
Resource Management
Resource Management is the efficient and effective deployment of an organization's resources in the most efficient way possible , maximizing the utilization of available resources to achieve organization goals. Such resources may include tangible resources such as
Tangible Resources
It can also include ideas, making sure that people are assigned to task that will add value and not have too much under utilization. These include
Ideas ..
What is Lean
Simply, Lean means creating more value for customers with fewer resources. ... Lean is the revolutionary superefficient production system pioneered by Toyota that simply eliminates waste. The core focus of "Lean" is to vigorously eliminate Wastes.
1.COMPLEXITY 2.LABOR
Make Simple Complex solutions that and are harder to manage. Eliminate all unnecessary "movement" and steps of people.
3.OVER PRODUCTION
4.SPACE 5.ENERGY 6.DEFECTS 7.MATERIALS 8.IDLE MATERIALS
Produce only the amount the customer wants and when the customer wants them.
Conserve space by improving poor arrangement of equipment, people, workstations, material storage, parts in-process and finished inventories Operate equipment and use person-power only for productive purposes. Avoid excess power utilization and unproductive operations. Strive to achieve the goal of no rework ever....no mistakes, rework or defects. Convert all material into products; avoid scrap, trim excess or bad raw materials. Nothing sits so there is a steady flow to the customer. Idle inventory including raw materials in any form, information, work-in-process inventories and finished goods is WASTE. Eliminate days, long setups and unplanned downtime of equipment, process and people. These often result from poor specifications, missing parts or information, late deliveries and inadequate training. Eliminate the movement of materials or information that does not add value to the product, such as double and triple handling of goods and needless movement of information. Eliminate condition/situation/environment that has tendency to cause danger or invite Safety Hazards
9.TIME
10.TRANSPORTATION
11.SAFETY HAZARDS
Causes of Waste
Layout (distance)
Long setup time Departmental Structure Poor maintenance practices Lack of workplace organization Poorly documented work methods Lack of adherence to established work methods Historic supervisory roles Irrelevant performance measures Complex production planning and scheduling systems
Red-Lining
Walking
Expediting
Invoices
Measuring/Checking Repackaging
Paperwork
Value Added
Necessary
Value Added Necessary
Teaching, coaching, disseminating right information
vs
Typical Organization
VA
NVA
Traditional Improvement
VA
NVA
Minor Improvement
VA
NVA
Major Improvement
Time
YESTERDAY
When we add value we also add costs.
Price to Customer If we want to make more profit we increase price
$$$$$$$$$$$$$$$$
Profit
Cost to Make
Traditional Principle of Cost: Cost + Profit = Price
Profit
Cost to Make
Lean Principle of Cost:
The challenge
We need to be able to do three things well, all at the same time!
Reduce Cost Reduce Lead Time Improve Quality
Production Costs
Customer Price
Net Margin
Cheaper
Faster
Better
Requires a new way of thinking. Training in new methods. Leadership and commitment at all levels. Implementation Just do it! Need to do more than talk. We learn by doing. Improvements dont have to be expensive.
Lean Principles
Lean Principles is a methodology, modeled from a Toyota manufacturing strategy that eliminates waste to reduce cost, improve quality and deliver performance. Lean is Continuous Improvement without adding Cost
Inventory
People Space
5SSIMPLE HOUSEKEEPING
Outlines: 5S as a Foundation of Lean 5S Definition
Seiri -
Sort (Visibility) Seiton Simplify (Visibility) Seiso Sweep (Cleanliness) Seiketsu Standardise (Adherence) Shitsuke Self discipline (Sustain)
Delivery
Lean System
Lean Manufacturing System is the revolutionary super-efficient production system pioneered by Toyota Motor Company. The core focus of "Lean" is to vigorously eliminate Wastes.
Material
SWIP
Operational Availability
Machine
Kaizen Methodology
5S Definition
5S is a method for organizing a workplace, especially a shared workplace (like a common floor or an office space), and keeping it organized. Its sometimes referred to as a housekeeping methodology, however this characterization can be misleading, as workplace organization goes beyond housekeeping.
5S Definition
5S Represents 5 Japanese terminologies Seiri, Seiton, Seiso, Seiketsu & Shitsuke 5S is a philosophy and a way of organizing and managing the workplace towards an organized, clean, high-performance environment with the intent to improve efficiency by eliminating waste.
5 Ss.
Benefits of a 5S Environment
It gives Ability to understand the status of a area in 5 minutes or less by simple observation without use of computers or speaking to anyone.
5S 1st Seiri Sort (Organize) 2nd Seiton - Simplify (Visibility) 3rd Seiso Sweep (Cleanliness) 4th Seiketsu - Standardize (Adherence) 5th Shitsuke - Self-discipline (Sustain)
Our Workplace
Lets take a quick look
Take
5!
Necessary & Unnecessary items are mixed together in the same workplace
Necessary & Unnecessary items had been seperated within identified work area (including inventory)
Only Necessary supplies, tools and items are stored in the Work Environment.
Why do 5S
5S are 5 necessary
disciplines for maintaining a visual workplace.
To take out unnecessary items either sort, red tag or dispose them
5S Red Tag
Red Tag Sample 5S Red Tags are used to keep the process of change going throughout the 5S program while remaining organized in the process. These 5S Red Tags are used for visual management of a workspace, clearly marking items that need to be moved creating workplace organization.
To arrange necessary items in a proper order so that they can be easily picked up for use
Consideration: Visual aids are encouraged in order to help understanding and minimize complexity. Labeling locations where necessary items are kept when not in use, especially moveable items. Labeling drawers and notebooks to identify their contents.
To maintain a high standard of housekeeping and workplace organization at all times Visual checks to maintain the process
Standards so management can evaluate performance Necessary to enforce discipline Standards for diagnosis, self-evaluation, a necessity to enforce discipline Buy in" With buy-in, discipline isnt necessary
Benefits of 5S
5S makes workplace more pleasant 5S helps in work efficiency 5S and safety go hand-in-hand
Flex Blame the Muscles Give up worker Throw fits Blame the Measure Show Boat Cover up Tamper with the Measure
Intimidate
Set goals
Grovel
Be clueless
Communicate Provide the Observe the process direction Find the Waste right tools
2.
DURING KAIZEN EVENT 1. Keep update on what everyone is doing 2. Chart takt time and cycles time during time studies 3. Coordinate for final presentation AFTER KAIZEN 1. Compile hard copy 2. Complete follow up checklist (Kaizen Newspaper)
Team members
Team work and support Kaizen Train the team on Lean methodologies 5s, quick changeover, mistake-proofing, cell design and kanban. Arguments that need to be addressed
Good on paper BUT.
What is Kaizen
KAIZEN = CONTINOUS IMPROVEMENT
In Japanese KAI ZEN Change Good KAI ZEN = Change for better
The small, gradual, incremental changes applied over a long period can be add up for a major impact on business in the future.
Attitude is Everything
Take
5!
KAIZEN at School
Schools are inundated by initiative after initiative in education, each seemingly polarized and disconnected- yet expected to somehow marry a system designed for industrial revolution in a digital renaissance. Change, when it occurs, needs to be managed. Teachers, are products of a previous education system, mostly before the Digital Revolution was introduced. We need to think of how we prepare our children to become lifelong learners in these fast pave technological change era. By implementing the Kaizen philosophy we can attempt to bridge the educational dichotomy and link the importance of structure with the need for creativity. Change needs to happen continually in small evolutionary steps. Surely, too, there is need for it in education.
Question to ponder
Question. Why do a lot of schools use a system of ringing
bells to stop or start. Is it to ensure order?, or is it to prepare the children for a profession which requires clocking in and out? Is it, in actuality, an acclimatization tool? Was its original purpose to provide them with a means of knowing when to be somewhere when Watches were a thing for the middleclasses and affluent adults? Surely we need change to move with the times by looking at the building blocks of the system and addressing each one analytically. We are not suggesting that there is a need for a change to complete removal of systems. We believe that children need structure in order to learn.
We need to change for the better to adapt to meeting current demanding needs at the same time not compromising the future to meet their needs.
Why Kaizen
To continuously eliminate waste without removing the value added activities in the process
Waiting
Processing
Inventory
Transportation
Take all FOUR
Movement
MUDA
Defects
Over Production
I nee d ON E!
How to Kaizen
Focus on doing
Gradual, unending improvement, doing little things better every day, setting and achieving ever higher standards
Litter
Litter is the one mandatory topic in the Eco-Schools Scotland programme. It's a very visible problem - it's easy to see how a playground awash with crisp packets and chocolate bar wrappers can give a bad impression of the whole school. However, by tackling the litter problem, both pupils and the local community will quickly notice improvements in the school's appearance and image. Cleaning up will also help to foster a sense of personal pride and responsibility in pupils.
recycling
Keep
Activity
Recycling Kaizen
Recycling at school is an easy step you can take to help the environment in three main ways: Reuse and Recycle
Less waste in landfill sites Turning waste into new products! Less rubbish- fewer landfill sites, free up more land. Save energy and raw materials Recycling uses less energy than making items from scratch, eg- aluminum can saves 95% energy needed to make new. Help tackle climate change Reducing Carbon dioxide is released into the atmosphere -cuts amounts of methane, a greenhouse gas given off by biodegradable materials as they rot under pressure
How much waste does your school produce? - hard to visualize how much and the sources of it. Average secondary- 22kg/pupil each year. Primary schools higher - 45kg/pupil. What types of waste are produced? - just two categories: Recyclable and non Recyclable Paper, card, food wrappers / containers Food waste Knowing how much of each material your school produces will help you to prioritize -which materials to recycle -what size bins your school will need.
Common forms of litter (or trash) include aluminum cans, plastic bags and bottles, paper products, used food containers, unwanted food, used papers and more. Litter can collect on drains, causing potential flooding by not allowing water to enter fast enough during a storm into drain to rivers, lakes and streams. When litter is washed into creeks and streams, it can impact aquatic life. This pollution can have harmful effects on drinking water supplies, recreational use, and wildlife. Make sure that your trash is properly disposed of and never litter. If you spot trash, pick it up and dispose of it properly! Do not rinse it down the storm drain or broom ,blow it down a drain.
Bin locations (where) - as close to the source of waste as possible e.g. a paper recycling bin next to photo copier/printer. -Recycling points and rubbish bins side by side. Types of recycling points -use the data from your waste audit to help you decide what type, size and quantity of recycling bins to suit best. Consider who will empty materials internally into external facilities, how they will do it, what equipment they will need and how often it will be done. Label recycling points (Visual) -label recycling points clearly, so that everyone knows where they are and what should go in them. You can use the easily recognisable Recycle materials to support your schools recycling scheme, including awareness posters and recycling point signage. Visit other schools to see examples of how they manage their recycling systems. To make recycling as easy as possible:
Keep it going
4th Seiketsu- Standardize (Adherence)
Designate Staff responsible for your recycling scheme to keep the momentum going. Role
- monitor and improve the scheme, with the help of an eco group - oversee people and activities across the rest of the school. Have a dedicated team and try to add something new each year - like printer cartridge or mobile phone recycling. Show other schools around what can be done, makes everyone in your school more keen to recycle more! -Liaise with the recycling monitors, cleaners and site manager/caretaker to monitor frequency of collection. Understand how much your school recycles and whether it is increasing or dropping.
This activity can be used to help set up a new recycling scheme, or to identify ways to improve an existing one. A follow up activity to the waste audit, pupils get to analyse real data from the waste audit, identify waste 'hot spots' in the school and brain/trystorm solutions to reduce the most common types of waste at school. They will produce an action plan, identifying tasks, responsibilities and time scales.
Benefits of Kaizen
to the Organization
Eliminates hidden cost 11 wastes Improve value added Quality, Cost & Delivery to YOU Improved work place eliminate unnecessary movement & delay with Visual Management Improve the best methods
YOU HELP the ORGANISATION to meet QCD
5S LEVEL
Sorting Simplifying Sweeping Standardizing Self-Discipline Sorting Simplifying Sweeping Standardizing Self-Discipline Sorting Necessary and unnecessary items are mixed together in the work area Tools, supplies and materials are randomly located factory or office equipment is in poor repair. The work area is disorganized, unsafe and inefficient Work area and processes are not documented and work is completed as individuals not teams minimal attention is spent on the work environment in organization, cleanliness and neatness. There is no 5S awareness Necessary and unnecessary items have been separated within the identified work area (including excess inventory) A designated location has been established and agreed to for items found necessary from sorting Physical and visual sweeping is being implemented to maintain and improve work area organization, cleanliness and neatness Sorting, simplifying, and sweeping documentation has begun and is readily available and visible to area users Area users understand the basic 5S principles and are attempting to follow and implement 5S. Teamwork has begun.
Level 2 Level 3
Level 1
Only necessary supplies, tools and equipments are stored in the work environment Visual controls are in place to keep the necessary organized. Work processes are being simplified for competently skilled Simplifying employees Work/break areas are physically and visually cleaned and inspected on a regular basis to ensure area safety, equipment Sweeping functionality, supplies and work place organization is in a ready to use state The work environment is standardized to an organizational level. Sorting, simplifying and sweeping activities have been documented and are visual and easily understood. Work processes are discussed, standard work is being implemented and Standardizing improved upon. All 5S agreements and practices are part of daily management. Area users clearly keep the work environment neat & organized. Self-Discipline Teamwork is evident. A dependable, documented method has been established to maintain the work area free of unnecessary items and stocked with what is necessary. Shop environments have established Lean Manufacturing Technology. A dependable, documented method has been established to maintain a visual control of all necessary items and processes A dependable, documented method has been established for area users to follow, fix and review work, tools, equipment and the environment. Work processes and work environments have been documented for peak efficiency. Improvements are shared with others as they occur.
Sorting Simplifying
Level 4 Level 5
Sweeping Standardizing
Self-Discipline The area users understand and follow all 5S documentation. The team is striving to improve the work environment and processes. Sorting Simplifying Sweeping Standardizing Employees continually review the work environment to seek and improve what is necessary or unnecessary Employees continually review the work environment to seek and improve visual understanding and simplifying of processes Employees continually review the work environment to seek and improve ways to prevent cleaning and maintenance Employees continually review the work environment to seek and improve workplace organization and standard work processes All 5S practices are followed by 100% of area users. All area users understand and continually seek to update and improve upon Self-Discipline all 5S activities. Teaming is an inherent part of the work culture.
of
Simplify
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Sweep
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
Total
Previous Total % (+ / - )
Take
5!
Project-Based Learning Projects can show students how disciplines as diverse as English, science and math are interrelated - can be developed to accommodate almost any curriculum. For example, A science teacher builds an Electrolyser with the students to demonstrate Electrolysis of water with soda to its gases form , who learned all of the skills that accompany the built and implementation and were engaged in the process. The students enjoyed the recognition the project and gained confidence in their abilities.
Field-Based Learning Practice skills in a realistic setting, more likely to see the big picture behind what they are learning. Field-based learning provides that opportunity. An innovative program gives students a chance to perform work in a real-life setting. For example, students who are learning about ancient history might spend time working on an archeological dig in the area. Mentoring Mentoring is an innovative practice being implemented in schools across the nation. Often, mentoring consists of experienced teachers assisting teachers who are new to the field. Mentoring programs train students to mentor other students are on the rise - helping new students to integrate into the school, assist in conflict resolution and do peer tutoring. Mentoring provides opportunity to be leaders and can help unify a student body.
Self-Sufficiency Many schools in third-world countries are working to become selfsufficient to ensure their survival. In the US, self-sufficiency is an idea that can free schools from unwelcome regulation such as state-mandated tests. Self-sufficient schools require students and teachers to maintain the buildings and grounds as well as work to produce a marketable product. Most often, this involves agriculture. Students in self-sufficient schools have the opportunity to learn economics, agriculture, marketing and other skills in a authentic environment. Read more: Innovative Ideas in Schools | eHow.com http://www.ehow.com/info_7896295_innovative-ideasschools.html#ixzz1rcnwyICJ
Timothy Wooi
Principal Consultant for Lean Management. Certified Kaizen Specialist & hands on TPM Facilitator with 30 over years working experience.
Provides Technical Consulting Services on Lean Equipment Fabrication, TPM, Kaizen & Moonshine set up. Mechanical background & DIY handyman who loves Green Living & Outdoor activities. Builds most of his stuff by Recycling idle resources to eliminate waste and promote Green. Develops Tims Waterfuel, an alternative fuel supplement using HHO Generator that adds power reducing Co2 emission. An NGO Community worker for Prison, Drug Rehab and leader of CREST North Malaysia, an organization that respond to Crisis & Flood.
Add: 20C, Taman Bahagia,06000, Jitra, Kedah, Malaysia Email: timothywooi2@gmail.com Office: 04 9171476 H/p: 019 4514007 (Malaysia)