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Her guidance helped me inall the time of research and writing of this thesis.I am also indebted to the members of Hoa Tho-Hoi An Garment Joint stockcompany, Mr.. .182.1.1.The History for
i ACKNOWLEDGEMENT Foremost, I would like to express my sincere gratitude to my advisor Ths.Lan Linh Huynh for the continuous support of my thesis, for his patience, motivation, enthusiasm, and immense knowledge Her guidance helped me in all the time of research and writing of this thesis I am also indebted to the members of Hoa Tho-Hoi An Garment Joint stock company, Mr Phuong Duc Nguyen together with other member in department of administrative organization for the many valuable discussions that helped me understand my research area better Last but not the least, I would like to thank my family, all the people who have supported me to completethe research work directly or indirectly ii TABLE OF CONTENS ACKNOWLEDGEMENT i TABLE OF CONTENS ii LIST OF TABLE v LIST OF FIGURE AND CHART vi ABTRACT vii RESEARCH PROPOSAL viii CHAPTER 1: LITERATURE REVIEW ABOUT 5S SYSTEM .1 1.1.Definition of 5S System 1 1.2.Benefits of 5S System 1 1.3.Component of 5S .3 1.3.1.SEIRI 3 1.3.1.1.Benefits of seiri step 4 1.3.1.2.Primary tools for the Seiri step 4 1.3.1.3.Tips for implementing a seiri 7 1.3.2.Seiton 7 1.3.2.1.The benefits of Seiton 8 1.3.2.2Principles of Seiton .8 1.3.3.Seiso - shine 9 1.3.3.1.Practice seiso 9 1.3.3.2.Steps of seiso 9 1.3.4.Seiketsu - standardize 10 1.3.4.1.The benefits of Seiketsu 10 1.3.4.2.Methodology of Seiketsu 10 1.3.5.Shitsuke- sustain 11 1.3.5.1.The benefits of Shitsuke 11 1.3.5.2.Tools to Shitsuke 5S implement .11 1.4.System implementation 14 1.4.1.Pre-Preparations 14 iii 1.4.2.CEO’s Official announcement 15 1.4.3.Big cleaning by all coleague .15 1.4.4.Initial sort 15 1.4.5.Daily seiri- seiton-sort 15 1.4.6.Periodic audits on 5S 15 1.5.The relationship of 5S components 16 1.6.Some things to keep in mind when implementing 5S 17 1.6.1.Keys to successful implementation of 5S 17 1.6.2.Difficulties to implementation of 5S 17 CHAPTER 2: ACTUAL SITUATION ANALYSIS OF THE 5S IMPLEMENTATION IN HOA THO-HOI AN GARMENT JOINT STOCK COMPANY ( 2014-2015) .18 2.1.Overview about Hoa Tho - Hoi An Garment Joint Stock Company .18 2.1.1.The History formation and development of HoaTho Hoi An Garment Joint Stock Company 18 2.1.2.Functions and responsibilities of the company 20 2.1.2.1.Functions 20 2.1.2.2.Responsibilities 20 2.1.3.Oganizational structure of the company .21 2.1.3.1.Oganizational structure 21 2.1.3.2.Manufacturing Organization Structure 22 2.1.3.3.Function and duties of the the management level department .23 2.1.4.Technological production process 24 2.1.5.2.Human resource situation in the Company .27 2.1.5.3.Situation about technology equipment 28 2.2.Actual situation analysis of the 5s implementation in hoa tho-hoi an garment joint stock company .30 2.2.1.Pre-Preparations at Hoa Tho- Hoi An joint stock Garment Company 30 2.2.2.Implementation phase 31 iv 2.2.2.1.Announces implement of 5S and Organize a Big cleaning by all colleague 31 2.2.2.2.Implementing initial sort 31 2.2.2.3.Implementing daily seiri- seiton-sort .32 Table2.9: Regulation about seiri- seiton-sort implementation of the company 32 2.2.2.4.Implementing shitsuke or sustain 34 2.2.3.Stages of Implementation assessment and evaluation results 39 2.2.3.1.Results of 5S implementation assessment at Hoa Tho- Hoi An joint stock Garment sompany 39 2.3.General assessment of the 5S management system in Hoa Tho-Hoi An joint stock garment company .47 2.3.1.Achievements 47 2.3.2.Limitations 48 2.3.3.Cause of limitations 49 CHAPTER3: SOLUTIONS TO ACCOMPLISH THE 5S MANAGEMENT SYSTEM IN HOA THO HOI AN JOINT STOCK GARMENT COMPANY 51 3.1.5S Implementation are true and lasting 51 3.1.1.Regeneration methods .52 3.2.Implementing the 5S program must be coupled with improvements 55 3.3.Solutions about people 57 3.3.1.Solutions to enhance through 5S communication 57 3.3.2.Training Solutions 59 3.4.Solutions about management 5S team 60 CONCLUTION 62 BIBLIOGRAPHY AND REFERENCE 63 v LIST OF TABLE Table 2.1 results of the Company during 2013- 2015 .25 Table 2.2 Number of employees of the Company according to department 28 Table 2.3 Situation about technology equipment of company 29 Table2.4 Regulation about seiri- seiton-sort implementation of the company 32 Table 2.5 The criteria for evaluation 34 Table 2.6 5S reward for 14 sewing lines 36 Table2.7 5S evaluation form 38 Table 2.8: The situation of work safety in the production process: 40 Table 2.9: 5S assessment based on the violation errors 42 Table 2.10: 5S assessment based on the number of violation errors 43 Table 2.11: Assessment average scores for the month 44 vi LIST OF FIGURE AND CHART Figure1.1 : Red/yellow Tag samples 5 Figure 1.2: Signage Strategy 13 Figure1.3 : The relationship of 5S components 16 Diagram 2.1: Organization chart 21 Diagram 2.2: Manufacturing Organization Structure 22 Diagram 2.3: Technological production process 24 Diagram 2.4: Cutting stage .24 Diagram 2.5: cutting stage 25 Figure 2.13: before/ after implementing 5S at office 39 Figure 2.15: Applied sorted according the 5S trace lines and bins in warehouses, workshops 41 Chart 2.17: 5S assessment based on the violation errors .43 Chart 2.20: Assessment average scores for the month 44 Chart 2.21: Assessment average scores for the month 45 Figure 3.2: 5S regeneration stage 51 Diagram 3.3:Cause-and-effect diagrams at Hoa Tho- Hoi An 53 Figure 3.4: 5S Map illustrations in sewing workshop to avoid violations 54 Figure 3.5 : illustrations in cutting workshop 54 Figure 3.6: Seiton by current methods of Hoa Tho-Hoi An 55 Figure 3.8 : PDCA (plan–do–check–act ) cycle of Dr Deming 56 vii ABTRACT 5S is a systematic technique used by organizations comes from five Japanese words; Seiri (sort), Seiton (set in order), Seiso (shine), Seiketsu (standardize), and Shitsuke (sustain) It stands for improving the order and cleanliness, and creating comfort and a safe working environment The aim are to increase the productivity of labor and improve the efficiency of the work, to ensure the health and safety of workers, workers felt the workplace was at his home, which helps people more interested in plants It also provides useful visual evidences to obtain more firm results There is a real need for empirical studies in field of new management systems and their impact on company’s performance The aim of this thesis was to propose solutions to improve the efficiency and to maximum benefic of apply 5S and to accomplish 5S management system In addition a plan to expand this 5S management system to 5S program must be coupled with improvements Assessment method base on establish the 5S standard is used and data collection is done by Synthetic observation The results of this research obtained from a comparative measurement of organizational performance before and after 5S implementation The results show that 5S is an effective tool for improvement of organizational performance, regardless of organization type, size,its production or its service Consequently, The results of this thesis confirmed the 5S management system will be upheld through internal audits and standardized 5S to achieve continuous improvement and higher performance Keywords: 5S; quality improvement viii RESEARCH PROPOSAL 1 The thesis’s necessity The trend of deep integration into the world economy has been created competitive pressures increasingly fierce for most businesses In this context, in order to survive and grow, businesses must active seek solutions to improve productivity and competitiveness of their enterprises To meet customer needs, many companies have applied a number of management tools in production and business activities, and have achieved certain success On the other hand, primary function of the Hoa Tho Garment Joint Stock Company is the production by processing form such as jacket Products are exported to many countries around the world such as USA, EU, Japan, Taiwan, Hong Kong, China So, customer are mostly perennial customers, prestige, requires high product quality, accurate delivery Therefore, from the early days of production the company has carried out the management method of Japan and especially the 5S management method However, the 5S method is a method of Japan but it actually executed in Vietnam Thus, it isn't suitable points Furthermore, 5s are applicable for the majority of staff are Vietnamese So there are many problems that arise in the process of implementing and maintaining of the 5S method in Hoa Tho - Hoi An Garment Joint stock company So, with a large role as well as the benefits that 5S activities brings , and inadequacies exist in this system, I hereby choose the topic “Solution to accomplish the 5S Management system in Hoa Tho - Hoi An Garment Joint Stock Company’’ as the research orientation for my thesis purpose to promote the strengths and overcome these limitations exist, create impetus for the development of theH oa Tho - Hoi An Garment Joint Stock Company in particular and business organizations in general 2 Research objective Based on the study, analysis, and evaluation of actual situation of 5S management system in Hoa Tho- Hoi An Garment Joint stock Company, ix construct scientific foundation for solutions to accomplish 5S management system in company 3 Scope and research subject Research subject of thesis are the 5S management system of Hoa Tho- Hoi An Garment Joint stock Company Scope: The scope of this study limited by 5S management activities of Hoa Tho- Hoi An Garment Joint stock Company start from applying 5S management system (2/2014) to in December, 2015 4 Research method Research based on theoretical basis about 5S management system Data collected by research method about secondary data: Secondary data was collected in Hoa Tho- Hoi An Garment Joint stock Company includes provisions on 5S documents, profiles, results from internal evaluation of the company and outside secondary data sources as textbooks and references Synthetic observation method: based on observations of the investigation These observations have been obtained by engage in the actual situation of company Combined with tools for exploration, taking photos to assess and offer solutions 5 Thesis structure The thesis is organized as flow Chapter 1: Literature review about 5S system Chapter 2: Actual situation analysis of the 5S implementation in Hoa Tho -Hoi An Garment joint stock company ( 2014-2015) Chapter 3: Solutions to accomplish the 5S management system in Hoa Tho- Hoi An Garment Joint stock company 1 CHAPTER 1: LITERATURE REVIEW ABOUT 5S SYSTEM 1.1 Definition of 5S System In Lean manufacturing tools, KAIZEN is a selection of better means or a change of current method for achieving an objective Steps to implement the activities of KAIZEN are eliminate- reduce- change (The Japan HR Association Definitions of KAIZEN) There are various other types of kaizen that you can use within your company.5S System is one in best of Kaizen tools And 5S is the one of the essential steps in motion and bring about a flourishing Lean culture according to Cooper Et al (Cooper, 2007) Dictionary definition, an organizational methodology originating in Japan that, when implemented, reduces the waste of resources and space while increasing operational efficiency The 5S elements include Seiri, Seiton, Seiso, Seiketsu and Shitsuke translated into English, are Sort, Set in Order, Shine, Standardize and Sustain and are applied in some companies' efforts to achieve "lean manufacturing" In fact, the 5-S concept was originally developed by Takashi Osada in the early 1980s3 According to Osada( Osada, 1991), 5-S practice is intended “to organize the workplace, to keep it neat, to clean, to maintain standardized conditions, and to maintain the discipline that is needed to do a good job” and “ 5S is a system in which to reduce work and optimize productivity and quality through maintaining and orderly work- place” 5S is a useful method for founding an organization and spread out a design and can improve communication and help employees to develop their characteristics to decrease, downtime, lead time, inventory, defect, injury and associated costs (K.Tsuchiya, 1998) Result the study of Becker J.E (Becker,2001) indicates that 5S technique is an effective way to improve health and safety standards, environmental performance and housekeeping 1.2 Benefits of 5S System Employee benefits: