Effective application of Kaizen – 5S program at Z175 factory

The application of innovative tools to improve productivity, create quality products, reasonable price, meet the needs of customers is an urgent requirement of businesses. Therefore, recently realized the benefits from kaizen and 5S program, so as early as October 2016, Z175 factory in collaboration with Vietnam Productivity Institute (VNPI) organized training classes and implemented the application of 5S and Kaizen practice to the production and business processes of the factory.

The factory’s management has proposed many solutions to implement the 5S program with the spirit of “change to development”. Initially, organizing the launching ceremony of the 5S practice program, general cleaning of the working area. Then, establish the 5S Board to supervise the implementation; direct the departments and workshops to plan the deployment. Organizing the contest to create slogans applying the 5S program, in order to improve the initiative, creativity, awareness and responsibility of all officers and employees throughout the factory. At the end of the contest, there were more than 200 slogans on 5S program practice drawn from the labor and creative process of cadres and employees.

In October 2018, the factory continued to cooperate with consultants to apply the 5S program in combination with Kaizen in the production and business process. The organization launched the Kaizen-5S Program. Established the CI and Kaizen group of factories; at the same time, direct the Kaizen team to develop a plan to open Kaizen with the focus on each production line; mobilize cadres and employees to focus on improving technology, machinery and equipment, automation, reducing waste, improving productivity and product quality. The 5S department of the factory regularly inspects, evaluates, scores each department, rewards, severely sanctions, puts the results of the collective implementation, commands of departments, departments and workshops into emulation targets and regulations on salary of the factory.

After a period of implementation, the factory has gradually promoted production capacity, improved competitiveness and dominated the market; create a basis for the factory to develop technology investment strategy, effectively exploit machinery equipment, link new material research and new products, material technology with product technology, technology new technology. In particular, the factory has well implemented 3 Kaizen focus (conveyor belt production line, spare parts production, rubber sedating) of the CI group has completed 7/8 targets on the production lines. For example, the rubber conveyor production line, after the implementation of the Kaizen Program, the output increased by 1.8 times, the material cost calculated on the average volume = 3%; reduce the time ≥ 6 minutes / batch; increased OEE by ≥ 6%; class I product quality increased to ≥ 90%; measured energy consumption, the number of workers on the line decreased ≥ 10%; average income of dynamics on the line increase ≥ 5%. The number of Kaizen of officers and employees is applied to the production of 420 people. Labor productivity increased on average on the lines 1.5 times.

Through the practical implementation of the Kaizen-5S program in production and business, Z175 factory learned lessons learned. The combination of 5S implementation with Kaizen has created an add-on that promotes the program faster and more practical. Currently, the factory is applying a day spent 15 minutes, each month spends a day for 5S, 6 months spend a day of total workplace cleaning. In the process of implementation, it is necessary to have the drastic direction of the Board of Directors, and measures should be taken to manage and identify risks. Constantly caring, directing and maintaining effectively Kaizen-5S practice management system transforms from self-enlightenment into habit. Continue to look for new ways, creative application of advanced management tools to maintain and continuously improve, raise standards in management effectively, safely and minimize waste.

After the implementation of Kaizen-5S program, the factory has really created the values of working environment, productivity, quality of technical rubber products are increasingly improved, equivalent to products of the same type in the region and in the world, bringing jobs, stable income for employees , employees and employees The factory.

Productivity and Quality Office