nye RGC~ PRODUCTIVITY PROGRAMS PROGRAM FREQUENCY | PARTICIPANTS TARGET Monthy and/or quarterly for internal audit Veny saTisFACTORY Ys all employees ae Semannval for ‘ternal uit Rank@&Fle/ | 100% Partcpation Quarterly Section Heads/ Sha (AN- sep) office Staff/ | hinimum oft project / Engineers ora Section Heads/ Office Staft/ Production Stat au Annual edcton Sa | 4s yep coment DeptHead / Manager Lr te mans Shady Ye _fowdadin of teeqrhtion_wacens- IRGC GROUP OF COMPANIES 4S hadilers ~ pouty TS qgmaininy js ia agshy 2/14/2014THE FOUNDATION OF COMPETITIVE SUCCESS. “HOUSE KEEPING- A base for any improvement Even before you plan the direction you need to take, you must remove any obstacles to get a clear view of the current situation. @House Keeping enhances the results of other activities and simplifies every day operations. «House Keeping must become a habit. It must be continuous, or at least continual activity. 2/14/2014 as« WHAT IS HOUSE KEEPING > Systematic approach to better workplace. Involves arrangement, cleanliness, discipline and maintenance of standards. > Assigns a place for every thing and ensures everything in its place. 3 Is everybody's responsibility. > Is the starting point of any improvement activity. > Means easy retrieval of information. “WHY HOUSE KEEPING ? LESS EQUIPMENT DOWN TIME. >MORE USABLE SPACE. PASSAGE WAYS ARE NEAT AND CLEAN. ABNORMALITIES NOTICED AT A GLANCE. > ELIMINATES ACCIDENTS. PRODUCTIVITY IMPROVEMENT. 2/14/2014/WHY HOUSE KEEPING ? > EMPLOYEES FEEL GOOD IF THE WORK PLACE IS CLEAN. > SEARCHING IS AVOIDED. > TIME WASTED IN HANDLING REDUCED. > NO UNNECESSARY SUPPLIES. > LESS REJECTION/REWORK. > BETTER PREVENTIVE MAINTENANCE. THE NEED FOR A "5S" STRATEGY AgaAIISG 2/14/2014| SIMPLE BUT IMPORTANT ~ | CONCEPT @ @ 5 A NEAT AND CLEAN FACTORY HAS HIGHER PRODUCTIVITY. 5 A NEAT AND CLEAN FACTORY PRODUCES FEWER DEFECTS. 5S A NEAT AND CLEAN FACTORY MEETS DEADLINES BETTER. 5 A NEAT AND CLEAN FACTORY IS A MUCH SAFER PLACE TO WORK. THE FUNDAMENTAL TRUTH © IF WE CANNOT KEEP OUR r- WORKPLACES wh ® CLEAN ey @® ORDERLY ® ACCIDENT FREE © NOBODY WILL BELIEVE WE CAN PRODUCE QUALITY GOODS OR ATLEAST SERIOUS ABOUT PRODUCING QUALITY. 2/14/20145S is a systematized approach to organize work areas, keep rules and standards, and maintain | the discipline needed to do a good job. It utilizes workplace organization and work simplification techniques to make work easier, faster, cheaper, safer and more effective. The practice of 5S develops positive attitude among employees and cultivates an environmegy of efficiency, effectiveness and economy. 5S is a productivity program that stands for 5- Japanese words all starting with “S”. 5S means “a place for everything and everything in its place”. It is a process to create more productive people and more productive company through motivation, education and practice of 5S. 2/14/2014TAGALOG —SURIIN Zz JAPANESE “SEIRT ENGLISH SORT SARILING SIGURUHIN DISIPLINA ANG / smreTix KALINISAN SurrsUKE Aone gap e: Se1s0 [DISCIPLINE STANDARDIZE Serr0N SINUPIN SANITIZE/ ‘SWEEP STABILIZE . SETUP } Level: Active 5S Level2: Effective 55 ~ Putting 55 into Action = Make 58 a “Habit” ! Level3: Preventive 5S. - Increase the Level of 35! CONTINUOUS PROGRESS Il- Effective 2/14/2014LEVEL. 5S Sort ACTIVE 5S. Put 5S into action| Stabilize/Set up Sanitize/Sweep Standardize EFFECTIVESS | Make 55a habit Sustain Safety Increase level of 5S Save Planet Eart + A clean and well-organized workplace is high in PRODUCTIVITY. a : + A dean and well-organized workplace produces QUALITY products and services. + A clean and well-organized workplace reduces COST to a minimum. + Aclean and well-organized workplace ensures DELIVERY on time, * A clean and well-organized workplace makes employee MORALE high. + Acleas ane wellorganized svoukplace ss SAFE for people to workin. + A clean environment ENSURES HEALTH AND caren of the future generation. 2/14/20142/14/2014 THE FIRST PILLAR: % Sort Means That You Remove All Items From the Workplace That Are Not Needed for Current Production Operation. 1. SEIRI/ SORT / SURIIN - To take out unnecessary items and dispose it properly.+ Eliminate unnecessary items to make job easy. Eliminate storing of unnecessary items in the workplace. To free floor space for the required) items and reduce inventories. @ A tagging system is an excellent way to | free up valuable floor space and eliminate such things as broken tools, obsolete jigs and fixtures, scrap and excess raw material in shop settings and unneeded documents, file cabinets, old B correspondence, and office supplies or equipment in office and service settings. 2/14/2014 10+ Green tag means the equipment/material passed inspection and is safe for use. ° ¥e __means that the equipment/material is safe to use if certain requirements are followed. + Red tag means the equipment/ material is unsafe to use, defective and should be remove from the workplace either for discard or repai 2/14/2014 1v What items could be considered as unnecessary in the workplace? O Old Items without Value O Leftover Materials G Obsolete Items OF Unknown Item ” . O Defective/ Damage O Personal Items Q Dirt / Waste. Q Hazardous to Health a QO Ofhers: O Excessive Item Q Accident Prone Item What are the activities to be done for the unnecessary items in the workplace? O Eliminate/ Dispose Q Repair O Put to 5S Holding Area O Keep it in a Proper Place O Return to its Proper Place Q Endorse to the Concern Area 2/14/2014 122/14/2014 . Can you find any unnecessary thing cluttering up your workplace? Are there any unnecessary cables or pipes just leftin the area and prone to accident? . Are there any tools or materials left on the floor? . Are all unnecessary items sorted out, classified, stored and labeled? . Are all equipments and tools properly classified and stored? 13SEIRI WHY SORT IS IMPORTANT?? © AWORK ENVIRONMENT IN WHICH. = TIME » MONEY SPACE ENERGY & EFFECTIVE RESOURCES MANAGMENT © PROBLEMS IN WORK FLOW ARE REDUCED, COMMUNICATION IS IMPROVED, PRODUCT QUALITY IS INCREASED & PRODUCTIVITY IS ENHANCED. 2/14/2014 14THE SECOND PILLAR: “ Set in Order Can Be Defined As Arranging Needed Items So That ~ They Are EasytoUse ~~ k and Labelling Them So That They Are Easy to Find and Put away. STON 2. SEITON / STABILIZE / SINUPIN - To arrange necessary items in good order for use. A motto often used in the industry is: "A place for everything and everything in its @> | place”. ~ 2/14/2014 15SEITON --ARRANGEMENT THIS STEP ENABLES DETERMINATION OF THE TYPE OF STORAGE SYSTEM AND LAYOUT THAT WILL GUARANTEE THAT REQUIRED AMOUNTS OF NECESSARY ITEMS WILL BE EASILY ACCESSIBLE. 2SET THINGS IN ORDER BY CREATING PLACE FOR EVERYTHING . > PUT EVERYTHING IN IT’S PLACE . SEITON --ARRANGEMENT >KEEPING ACCESSIBILITY AS EASY AS POSSIBLE . USE THE PRINCIPLE OF WIDE RANGE AND SHALLOW DEPTH FOR STORAGE. > TIME SAVED IN SEARCHING. > TIME SAVED IN HANDLING MATERIAL. 2/14/2014 16PROBLEMS AVOIDED BY IMPLEMENTING SET IN ORDER © WASTE OF @ MOTION SEARCHING HUMAN ENERGY ~~ 5 EXCESSINVENTORY “ » DEFECTIVE PRODUCTS o UNSAFE CONDITIONS HOW TO PROMOTE GOOD ORDER Seldom used, enclose in a separate designated place. > THINGS NOT NEEDED: >No potential use, immediate disposal after careful analysis. > Potentially useful, move toa separate designated place. > Require special arrangement disposal. 2/14/2014 172/14/2014 | HOW TO IMPLEMENT SET IN ORDER © DECIDING APPROPRIATE LOCATIONS & LOCATE ITEMS IN THE WORKPLACE ACCORDING TO ‘THEIR FREQUENCY OF USE & PLACE FREQUENTLY USED ITEMS NEAR THE WORKPLACE. STORE INFREQUENTLY USED ITEMS AWAY FROM THE PLACE OF USE. & ALETGO ARRANGEMENT FOR TOOLS SO THAT THEY GO BACK TO ORIGINAL PLACE OF STORAGE, Prevent loss and waste of time. East to find and pick up necessary items. Ensure first come first in first out basis. Make production flow smooth and work easy. @ 18Organize the workplace in such a way that itis .... EASY to see, EASY to get, EASY to return. + Store goods/items for first-in-first out basis. + Everything must have its location. + Label items and their locations systematically, mark everything, * Separate special tools from common ones + Arrange things based on number and color (Put demarcation line) @ | | | 2/14/2014 19Put frequently-used items nearer to the user. Provide signs for abnormal condition or when help is needed. Keep space for safety equipment and evacuation passages clear. @ cL THE THIRD PILLAR: ¢% Shine Means Sweeping Floors, Whipping off Machinery, and Generally Making y Sure That Everything in the Factory Stays Clean. 2/14/2014 203. SEISO / SANITIZE/ SIMUTIN - To clean your workplace. SWEEP / SHINE ¢ Cleaning of the work place generally occurs in conjunction with the first two steps (sort and set in order). © Now that everything has a place clean the floors, walls, benches. * Look at ways to assist in the cleaning of the area e.g. Are their the right bins in the area? Are they being used correctly? ¢ Paint the structures and floor markings to identify specific work areas e.g. clearways, hazardous materials. 2/14/2014 2SWEEP / SHINE * Sweep your area visually; Wipe off equipment and personal-space surfaces Prevent accumulation of dirt, spills, crumbs, and dust Establish an area to keep personal-space cleaning supplies The idea is to clean up while the task is small - daily! SEISO - CLEANING >This step eliminates Dirt, Dust and other foreign matter to make the workplace clean. Clean Equipment,Furniture,Notice Boards Records Etc. > Keep the workplace Spotless. > Sweeping,wiping, polishing, painting Etc. 2/14/2014 222/14/2014 * Easy to check abnormality * Prevent machinery and equipment from deterioration. * Keep workplace safe and easy to work. . Are there establish cleaning responsi . Are there oil, dirt and dust that can be found at the floor and aisle of your workplace? . Are the waste/ garbage in your workplace not properly managed which can be harmful to . Are the light bulbs, mirrors and windows dirty if) your workplace? health? | 23THE FOURTH PILLAR: “ Standardize Is The Result That Exists When the First Three Pillars - Sort, Set in Order and Shine Are Properly Maintained. 4, SEIKETSU / STANDARDIZE / SIGURUHIN ANG KALINISAN - To maintain high standard of housekeeping. 2/14/2014 24