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IMPLEMENTATION OF SHADOW BOARD (TOOLS STORAGE)

SYSTEM AT WORKSHOPS

Group: Rodzidah, Hafiz, Nizan, Amir ~Department of Skills Development

(DSD),Ministry of Human Resources (MOHR), Malaysia~

INTRODUCTION

According to the internal audit report, there are many factors were found to influence the

efficiency of workshop, such as missing tools, misplacing tools, registered in and out

tools not tally, times taken to determine the missing items and etc.

In view of this, the management requires to find an alternative solution on how to

overcome these problems. This will help to lessen tiresome of workshop users, faster

inspection and locating missing tools swiftly.

The 5’S and Kaizen committee headed by Director himself agreed to introduce Shadow

Board (Tools Storage) system. The objectives of Shadow Board (Tools Storage) are as

follows:

i. To improve working environment in workshop;

ii. To improve learning environment in workshop;

iii. To lessen the tiresome of workshop users;

iv. To promote 5S awareness among workshop users;

v. To promote safety and health working environment.

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ACHIEVEMENT FROM THIS SEMINAR

In the Monozukuri process, we learn the art of manufacturing process beginning from

needs analysis of the customer towards finishing product. The philosophies of the study

visit at various polytechnics were Kaizen and 5S are the biggest enhancement towards

a new niche. This indeed will satisfy delivery service to the trainees.

PROBLEMS/ISSUES TO BE IMPROVED/UPGRADED AND THE REASON TO

CHOOSE THE PROBLEMS/ISSUES

Findings from site visit on selected workshop done by 5’S and Kaizen Committee are as

follows:

1. Tools were not arranged according to the size.

2. Tools were found scattered and disorganized.

3. Nonexistence of tools labeling.

4. Standard Operational Procedure not provided.

ACTIVITIES TO IMPROVE PROBLEMS

1. Innovation of tools storage by using shadow board (Kaizen Method)

2. 5’S activities e.g labeling, legend, numbering, SOP, standardization.

INDICATOR TO EVALUATE THE EFFECTIVENESS

1. Pick and Place time study

2. Questionnaire/survey with 5 likert scales

3. Auditing by internal and external auditor

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METHOD OF ACTIVITIES

1. Establish the Central Committee comprises of Director, Deputy Director and

Head of Department.

2. Establish Small Group Activities (SGA) headed by Head of Department, Head of

Unit, Trainers and Technician.

3. Establish Steering Committee headed by Director with members from Deputy

Director, Headquarter Officer, Head of Program and external member such as

National Productivity Centre (NPC).

PERSON IN CHARGE OF EACH ACTIVITY

1. Head of Department in charge of each Program.

2. Head of Unit in charge of each workshop.

TARGET GROUP OF THE ACTIVITIES

The target group of the activity will involve as follows:

1. Workshop of Automotive Technology

2. Workshop of Welding Technology

3. Workshop of Production Technology

4. Workshop of Fabrication Technology

5. Workshop of Electrical Power Technology

6. Workshop of Mechatronic Technology

7. Workshop of Electronic Technology

8. Workshop of Plastic Technology

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The activity will be piloted with Automotive Workshop Technology as benchmark

before implemented to the other rest of workshop. The outcome of the pilot activity

will employ according to the workshop condition. If needed, the activity will be vetted

from time to time to achieve the objectives aforesaid.

SUMMARY

The quality of training is the gist that customer would never compromise. In pre-training,

during training and post-training, workshop users particularly trainers have a

responsibility to ensure the items are secure and suffice. With the introduction of

Shadow Board (Tools Storage) System, managing inventory will be much easier,

precise and workload reduced. In addition, learning pattern to be more ‘Student

Centered’ (Self Reliance Learning), thus creating a very conducive learning

environment.