Implementation of Kaizen in the enterprises by Woreda level industrial

extension workers

Document exploration in Woreda 3

Introduction

Over all activity and implementation of Kaizen training by keeping the procedure in the

particular of Kaizen implementation presented as follows

1. DETME enterprise where found in Gulela Sub-City Woreda 3 proximity to the health

canter

2. DOBA/ATW enterprise >> >> >>> >>> >>>>

Implementation of ‘Kaizen philosophy conducted in the two enterprises which founded in

Gulele Sub-city at woreda – 3 leavel namely Lalibela Construction P.L.C. and Ralcon

construction P.L.C.

The full implementation package of Kaizen programme has been performed by the collaboration

with woreda and TVET college Kaizen team on the enterprises. The name of enterprise is

I. Lalibela Construction P.L.C Kaizen team which undertakes the full implementation

package Participants (implementers) namely had undertaken the continual support for

the sustainability of the implementation.

II. Ralcon construction P.L.C, The Kaizen team which undertake the full implementation

package namely;

1. Kaizen (scale productivity)

2. Identification of knowledge gaps and registration of those gaps

3. Assisting the concept of technology transfer

4. Job creation and market sharing among them.

The reports of the above enterprises include detailed job description and throughout the work,

the strength and weakness are analyzed by doing SWOT analyses.

General Work Description of Kaizen implementation

Starting from 16/04/04 E.C, inauguration of the enterprises, the implementation of Kaizen

philosophy was introduced but the presence of holiday rendered the framework. After assessing

their willingness, by forming a team (a group), we undergoes assessment on their willingness,

finally we started the job.

Detailed Work Description

Shop layout, According to the shop layout, categorizing and labeling of equipments were done,

new job store constructed. Arrangement done on raw materials, the class dividing was made by

table was demolished, Appropriate shelves and tables were assembled on their proper place,

Allocation of raw materials were done on the shelves both in / arrangement type and amount

Transferring the arranged raw materials in tool store

Cleaning the machines by benzene & compresses, Problem identification of malfunctioning

machines, cleaning the room

Appropriate disposal of the waste and waste storage on the boxes were done, Tools

arrangements, Kaizen board was done, Waste storage box was done, Skill gap/need assessment

time frame was done on the same date, Typing the arranged tools on compute, Posting them on

the billboard, Purchasing of conduit breaker

Training was given for accounting leather and the debt-credit capital was not registered properly

on the capital statement, but the registration process of cash flow statement is done based on the

daily basis. In addition, detail description, receipt no, cash, bank deposited, credit from

shareholders, raw material, registration fee from shareholders, fixed equipments, payable credit,

registration fee from new members, contingent deposit from shareholders, payable profit,

telephone & electric power bill (expense), stationery expenses, transportation expenses, salary

expense and other expenses were debited and credited.

In lalibela construction, the files model were compiled, other files which are properly handled

are: Personal profile of worker, Minute profile, Tender letter profile, we recommended them to

create a file of another box file models and purchase order form.

Work Description in Radical Construction

Arrangement of storage for machine and raw materials, Temporary shop layout drawing

preparation (preparation of temporary shop layout drawing), The metals and woods founded in

the shop were deposited outside of workshop for proper implementation of the work plan

Cleaning of workshops, Proper storage of raw materials, Proper assembly of machines based on

shop layout, Assembling two benches in the workshop, Proper storage of raw materials for metal

and wood work, Storing raw materials on their own appropriate place, Entry of shelves, Proper

identification of raw materials and put them on shelves, Expiry metal & woods were properly

disposed, Workshops, raw material storage, kaizen board, assembly room for machines, MDFC,

Direction indicators were prepared by compressor and posted

- Purchasing of conduit breaker, Electrical installation, Skill gaps were identified. These

are:

1. Accounting

2. Metal work

3. Wood work

4. Management & leadership

5. Bookkeeping

Ralcon Construction

Cabinet for entry letters, Purchasing order folder, Workers private profile folder, Minute folder,

Tender letter profile

The problem identified in both enterprises is that proper cleaning of working environment after

day-offs; lack of proper labelling of raw materials and produced goods; but by working together

the problem was solved. Electrical installation on ground was done. Lastly additional box files

purchasing proper utilization of them were recommended for them.

Benefits Encountered

Getting labeled goods within short period of time, proper cleaning of working environment

Missed materials and goods are easily accessible, current good manufacturing practice created,

time saved, Electrical installation that minimizes danger and working friendly

Proper labeling of raw materials and work goods on shelves in stores, Proper identification and

assembly of waste disposal, Expenses for purchasing of goods include:- Sanitary items,

Electrical items like conduit and breaker

Training need assessment tools were our questionnaire/interview

Purchasing of steel products & selling of wastes as of Kaizen implementation, First aid kits were

prepared for both enterprises, Business plan was prepared for both enterprises which include:-

Business transaction and expenses, Monthly work plan, Monthly operational/cost plan/ material

cost prepared, Cash flow plan was prepared

Strength and Weakness of Kaizen Implementation

1.1. Strength

Inauguration of industry extension in woredas, Active participation of workers and teachers of

woreda industry extension services, Proper implementation of Kaizen by forming cluster centre

among human resources, Forming team work and proper workflow among teachers in woreda

and TVET colleges, The work plan is specific, measurable, achievable, reliable and time bound

and it is effective

1.2. Weakness

Lack of safety precaution clothes, No budget for medication purpose, Accidents due to lack of

safety precautions, Lack of place for treating staffs, Lack of technology, equipments and

materials, Non-inclusiveness of professionals in industrial extensions, Presence of

implementation gaps due to long organizational structure, Lack of market opportunity, Need of

total dependency, Lack of participation of cluster centre

Limitation, Lack of willingness during implementation as of seven other enterprises did. Plan

implementation gaps, Lack of safety precaution clothes, Lack of continues training and

communication gaps between trainers with TVET teachers

Possible Problem solving strategy

Undertaking ideas for enterprises about Kaizen implementation, Fulfilling all the materials and

equipments needed by discussing the issue with respective and responsible stakeholders Solving

skill gap and identifying issues to be solved through long term & continuous training,

Recommending the enterprises to implement the workflow process and the training given

Solving or reducing knowledge, attitude and skill gaps through continuous training

Creating effective professional goal to be achieved, Issuing the nearby health institutions to

render better health far and treatment for them beyond rendering first aid.

Summary

Assets to be implemented for boosting productivity efficiency starting from 16/04/04 – 03/05/04

E.C are:- Sort – identification of raw materials for production and service, Stabilize – labelling

and storing beneficial assets, Shining – cleaning of workshop & equipments and materials,

Standardize – assuring quality for workshops, Sustain – keeping for continuity of Kaizen

philosophy

In addition

Kaizen (increasing production & productivity efficiency), Identification and registration of skill

gaps, Assisting them for technological transfer, Entrepreneurship & market opportunity creation

Other tasks include space management & keeping modern production flow project outputs and

impact is also their focus and the project all in all was SMART.

Even though the service of industrial extension the city administration of A.A particularly in

each sub-city and vocational school is started soon; many achievements have been observed.

Among such success full accomplishments Kaizen system takes the lion’s share. This system

helps this model in association with micro business activity. In addition with this industrial

extension gives to those micro-business associations’ short term training to improve their skill

business planning and financial management. This service has been implemented in each

Woreda and sub-city .Due to this each micro business enterprise has got good progress in their

activity.

Beside this, the industrial extension gives short term training for an employee and females and

enables them to have their job. In this respect Gullele sub-city Woreda 3 have done a good job

which can be considered as a model for other sub-cities. The administration creates close contact

with Vocational Schools to bring more trainers to be trained and finally enable them to start

their Micro Business services. Moreover, they also create contact with different NGO’s or

Charity Organizations to create good job opportunities for the trainees. Generally, the

management has made good progress in this year than before. The overall activities of that

industrial extension can be stated as follows:

A new machinery is donated to the newly emerged enterprises, and

The administration enables them to buy a new machine and begin their service that is

three Micro Finance enterprises each having 20 members has bought a machine with

25,000,000 Eth birr. The coast doesn’t include the saving account which is given to

them by saving and credit association of Addis Ababa.

Activities Performed Through Kaizen

The first and second round activities have been implemented for DTAM and Ras Emiru through

Kaizen Systems. We did it basically with their own ------------.Now we are following their

activities and still the following activities has been performed:

Shop layout Preparation of materials according to shop lay out, a decision was made on having a

new tool store have been implemented. Furthermore, the implementation of Kaizen continued

Re-arrangement of raw materials, Room partition. Arrangement of Chair, table and Shelf,

Arranging raw materials in accordance with quantity and Seat arranged raw material in tool

store, Cleaning materials with comprador and Dicdel, Identifying problems of dysfunctional

materials, Room cleaning, Kaizen board, Trashcan(Garbage), Stick quotations in timber,

Training in auditing.

Benefits of Kaizen

The process of finding material takes 10-15 minutes before arrangement, but after

implementation we were reducing 15 mints per single item materials hidden and poor -------

cleaning

Hidden materials found, creates conducive environment and time will be

saved.

Problem of installation will be solved.

After installation conducive, visible safe environment will be created.

The ware house re-arranged and all materials situated In a clear visible area.

Garbage prepared and situated in a specified area.

Expenditure for purchasing materials

Broom

Electrical materials such as Conduct breaker

Half kilo 5cm and 8cm nail purchased. The income was high after Kaizen

implemented because pieces of metal scrap sold.

Filling the gap by giving training such as filling, auditing management.

Sanitation undertake, first aid box a bounded plan pre pared. such plans

are:

Outcome which is planned monthly

Selling plan

Cash flow plan

Support given for those who need help

Concerning the enterprises implemented Kaizen continues follow-up support

Among the works in this year visiting, observing and assessing enterprises and

associations which implemented Kaizen such as Lalibella, Raccon, DETEMA wood and metal

enterprise. Accordingly:

1. Lalibella Wood and Metal Enterprise

Strangth: Place of the machine, organized office, cleanliness, their work flow is work

centered

Drawback: hand tool raw materials, Kaizen boards are twisted, misplaced in un proper

lace

Support: Give help, advice in order to arrange sitting materials in proper way.

2. Rlaccon Wood and metal enterprise

Strength: cleanliness the environs

Drawback: Manufacturing wood and metals products together misusing flow of work (is

not work centered), no Kaizen board, unwillingness of accepting expertise advice and

support.

Support: give advice to --------working rooms, give expertise support such as cleanliness

of work place.

3. DTM wood and meals Enterprise

Strength: Organization using the office is better, Work flow and cleanliness of shade.

Drawback: Misuse of raw materials and improper placing of hand tools.

Support: give advice for placing raw materials and hand tool

Regarding of the training

Industry extension within 6 month of Kaizen implementation, short term training of women

and unemployed in entrepreneurship conducted with the cooperation of TVETs in the first,

second and third round. After training conducted the trainees were organized in association and

start operation .Trainees are:

In terms of first round training:

The aim was to train 500 unemployed trainees, but 402 of them were trained in different fields in

Entoto and Shro Meda Technical and Vocational College with related to job creation and

business plan.

The coordinators work leaders got private plan beside 1 to 5 plans and a check list. Additionally

time is allocated for meetings to assess---------.During second round there was no attitude gap in

institution level because problems identified and solved in the first round training. Training is

conducted deliberately and trainees working privately, in factories and also in associations.

Kaizen Workshop management, business plan, work ethics, leadership, recourse management

------plan preparations credit and service, book keeping, market competency ,trainings given by

Vocational schools. The training conducted for SMEs by the Kaizen team in two rounds. The

first training conducted in the first two days but the second round was wider and it takes 1 week.

The training was vital to fill the gap.

Regarding the input more or less there had been no shortage excluding Computer and table. A

ground plus 4 building is underway by world Vision .The operation was lagging behind due to

absence of Engineer, but now the contractor hired engineers and the building process is taking

place on a large scale. In addition to this the charity organization is willing to help organized

trainees. Namely:

1. Unity Blocket Enterprise Private Limited Company with 15 members.

2. Yenege tesfa Blocket Enterprise Private Limited Company with 23members.

3. Entoto Blocket Private Limited Company with 20 members.

4. Jantekel Blocket Private Limited Company with 20 members.

And the total number of these associations is 78.After they organized themselves in associations

they requested to be aided by the following materials; Blocket production machine, Plastic pipe,

Spade, Spoon for concrete mixing, Glove, Wok uniform

This was presented for the charity organization with specification and they are waiting for the

purchase and delivery of the materials to begin their work.

In Shro Meda Training institution all the materials were purchased by World Vision. For all

departments machineries and accessories were purchased and the remaining is on process,

specifically for leather department many types of machinery were bought, but machineries for

shoe manufacture are not still purchased.

Woreda 3 Report on the Implementation of Kaizen

Introduction: Kaizen is being implemented in behind health centres found around woreda 3 near Menen

preparatory school the report was prepared by woreda 3 industrial extension servants found working in

woreda 2 & 3. This activity is aided by Industrial extensions for small scale enterprises modulated by

Entoto cluster. This is done in accordance with the growth and transformation plan of the country or its

implementation plays a vital basis for the economic growth. This is through well equipped manpower

technological transfer that is in accordance with the market situation of small scale enterprises and focus

on productivity, quality based products. The industrial extension implementation of 1st round Kaizen in

our woreda starts from Nov /10/2005 E.C – 29/03/2005 E.C. This was modulating with Entoto TVET

College for 2 enterprises. These are:

1. Ediget behibret dry food manufacturers PLC

2. Beza wood & metal work enterprises

The enterprises starts with 5 shareholders with initial capital of 15,000 from shareholders, nowadays the

shareholders are 11 and 5 full time workers with a total of 16 workers.

Problems encountered while implementation

Attitudinal problem, Proper utilization of working time, Limitation of planning, Limitation of fulfilling

some input materials

Skill gap, Communication / unity problem , Shortages of professionals in all discipline

Input , Lack of important inputs for the enterprise as a result quality problem, Lack of Amharic version

training materials, Improper utilization time, Safety materials shortage, Thines of attendance of trainee,

Lack of trainers (teachers) due to burden of work

Problem of the Enterprise

Attitudinal problems, Absolute dependency, Problem of work flow, Problem of time utilization

Skill, Gap of commercial planning, commercial leadership and material handling problem, Bookkeeping

and accounting problem, Machine operation and safety problem

Input, Lack of standardized machineries & lack of prevention tools, Lack of safety tools, Sanitation

problem, Problem solved from the enterprises

Attitudinal problem, By creating attitudinal & awareness change, dependency tied to be solved. Input

problems solved and material cost paid by enterprises, The training was as much as possible inclusive of

all stakeholders, Promoting continuous work flow system

Filling skill gap, Creating awareness on credit, Govern training on commercial leadership and

machine operation, Practices on inputs (implementation activities on input), Recommendation has been

given on the work flow process, As far as safety clothes were concerned, uniform should be used by

individuals, Procurement of materials that are not available in the shop (ordered to purchase shortcoming

materials)

Results Productivity Improvement, Arranged the working place and disordered materials and

recommended to work in accordance with proper work flow process, Appropriate working environment

created (made conducive working environment), Used transparent steel instead of electric light,

Prepare/installation of air conditioning system, Prepared waste material stock and trained on sanitation

safety

Summary

The Kaizen implementation given for the 2 enterprises proved productivity and conducive working

environment and transforms the enterprises for a betterment of their fruits [The Kaizen implementation

increased productivity conducive working environment for both enterprises] The five assets that are

implemented are:

1. Sort: identification of inputs for production and service

2. Stabilize: labelling of materials

3. Shining: cleaning machineries

4. Standardize: maintaining the already organized shops

5. Sustain:

Space management and keeping modern production flow, skill gap (need assessment and fill the gap,

using modern furniture desire)

Weakness of the Training

Effectiveness problems measured by policy, curriculum, facility of the training materials and

equipments training of trainers demand and supply, and market information. Lack of competency

for preparing training materials at the grassroots level Up to date facilities and equipment are

required Competency of trainers Limited involvement of the private sector and NGOs Limited

involvement of the private sector and NGOs, Not providing training on based on demand and

supply principle In adequate job opportunities Lack of information.

He continued that select an area the first step is to choose where you will conduct your first

Kaizen affair. You want to choose an area that will have an impact but not pose too many

difficult problems to solve in the beginning. Each event will teach you things that will make the

next incident smoother and easier to run successfully. Also, each event provides a training

ground for new team leaders. As people gain experience in running events, and as measureable

results accumulate in the areas where events have been run, it will become possible to tackle

more complex lines and difficult problems. Start slowly and build momentum as you gain

confidence and experience. You will get each time you do an event and so will your teams.

He further added that, you can choose several areas where you would like to start and compare

the merits of each. But during the implementation of the Kaizen event in the selected area the

enterprise can disseminate to other work station, and finally the enterprise will have the all

compound Kaizen implemented. This will ensure that you start with the best one first, based on

several criteria, and help you determine what will be next. Each Kaizen event should be chosen

in order to create a progression of results that support the enterprise the implementation of

Kaizen. There are a number of things to consider during area selection.

We are presiding the work of the Kaizen team; Select the team members, the team leaders’ first

responsibility is to select the team members. The team members are the people who actually

conduct the kaizen implementation. There should be a maximum of 15 people on the team. Team

members must be created depend on the task that each member is doing and also chosen for their

ability to work together and also because they understand and support the potential of the kaizen

implementation. Those who complain or belittle the potential will slow down or even block

success, especially for the first few events you implement.

Select the team leaders, after choosing the area and the problem focus for the team leader must

be identified. The team leader lead conducting Kaizen; he or she chooses the team members

prepare for the Kaizen implementation, creates the schedules, gathers the materials and tools, and

follows all event activities, helping with documentation and report we are keeps the team on

target, ensuring that they make objectives of the proper implementation of Kaizen. Team leaders

we have been assigned that we should have to be selected enough ahead of the implementation

so that they can rearrange their schedules to make leading the event their top priority.

Prepare the Team Leader, Team leaders will need to know the goals and objectives of the event,

the production requirements, and the expectations of team members. Information from past

events should be shared with the team leader, such as past problems encountered and gains

achieved. What we have to give the team leader should also be given information about what to

do in an emergency, safety rules related to the area, what to do when things bog down, how to

handle personality conflicts, and where to access needed data. In addition to sustain the team

members, the leader has a number of response and activities before, during, and after the

Implementation of the Kaizen training.

In order to have a big impact right away choose an area, that has activities that occur all over the

plant, that has a significant bottleneck or other major hindrance production flow, Where

everything is a mess

Train the team, Potential team members with a positive outlook may in the fundamentals of

Kaizen. All team members and the team leader need to be trained in the methods that will be

used or implemented during the event. Team leader is responsible for scheduling and

coordinating required training in advance of the event and for provision for the team members to

discuss and absorb what they learned. Training will be conducted mainly by the human resources

but it can also conduct by the training coordinator and team leader also.

Select a problem for improvement, Once the area has been selected, the focus for the kaizen

implementation must be decided. Be sure that you mark the boundaries of the chosen area clearly

and that you set and maintain the boundaries during the kaizen event. Talk to the people who

work in the selected area about the project and work with them in deciding on the problem to be

improved.

The reasons you chose this particular area for a Kaizen implementation probably included some

understanding of what is needed in this area. Now it is time to check your assumptions and

examine the conditions and the process used in this area more closely. In selecting a focus for the

Kaizen event several things need to be considered. Has 5S been conducted there? Should that be

the focus of the first implementation in this area or do you want to implement 5S more gradually

before conducting the event?

3. DETME enterprise where found in Gulela Sub-City Woreda 3 proximity to the health

canter

4. DOBA/ATW enterprise >> >> >>> >>> >>>>

DETME metal and wood production is a private limited company, which is located in Woreda 3

proximity to the health centre and their phone number is 0911431931, they are at the statues of

small and micro enterprise with 10 male and 2 female with a total number of 12 shareholders; in

addition to this the enterprise creates job opportunity for other employees which are10 in

number having 9 male and 1 female members. In terms of employment 7 of them are full time

workers while the other 3 are part-timers in the enterprise. The enterprise was inaugurated as of

2006 with initial capital of 1200 birr only. The machinery costs were 84700 and 17000 birr and

this contributed a lot in attaining the current capital exceeds to 143184 birr. They applied Kaizen

implementation in their enterprise by he help of Entoto TVET Cluster College in 2010.

The second one is DOBA and ATW metal and wood production a private limited company,

addressed at Woreda 3 aside the health centretheir phone number is 0911650215 level of their

statues is small and micro enterprise with 8 male and 2 female and with a total number of 10

shareholders. In addition to this the enterprise has created job opportunity for other workers

which constitute 8 male and 2 female members making a total of 10. In terms of employment

there are 2 full time workers and 3 part-timers. The enterprise was inaugurated as of 2009 with

initial capital of 1200 birr only; but making a great effort after the establishment and with a

greater achievement their current capital reached 720,000.00 Ethiopian birr. They applied Kaizen

implementation in their enterprise by the help of Ethiopian Kaizen institution in 2012. They were

implementing the Kaizen Philosophy properly. Despite their shortage of place for their

production, they stick to the stapes and discipline of the system. Since the most of them are

educated, their application is proper and their management system revealed a potential for never-

ending efforts for improvement in production values. They got an award from Ministry of

Science and Technology for their innovation of a machine which produce traditional cloth called

“Shma and Tibeb .” The machinery which they innovated reduced production time and created

comfortable working environment. Hence, they made modern types of production. The ordinary

type of production tools of wavers is traditionally by digging the ground which consumes time

and man power. Over all activity and implementation of Kaizen by keeping the procedure in the

particular of Kaizen event. presented as follows

Even though the service of industrial extension the city administration of A.A particularly in

each sub-city and vocational school is started soon; many achievements have been observed.

Among such success full accomplishments Kaizen system takes the lion’s share. This system

helps this model in association with micro business activity. In addition with this industrial

extension gives to those micro-business associations’ short term training to improve their skill

business planning and financial management. This service has been implemented in each

Woreda and sub-city .Due to this each micro business enterprise has got good progress in their

activity.

Beside this, the industrial extension gives short term training for an employee and females and

enables them to have their job. In this respect Gullele sub-city Woreda 3 have done a good job

which can be considered as a model for other sub-cities. The administration creates close contact

with Vocational Schools to bring more trainers to be trained and finally enable them to start

their Micro Business services. Moreover, they also create contact with different NGO’s or

Charity Organizations to create good job opportunities for the trainees. Generally, the

management has made good progress in this year than the before. The overall activities of that

industrial extension can be stated as follows:

A new machinery is donated to them, and

The administration enables them to buy a new machine and begin their service that is

three Micro Finance enterprises each having 20 members has bought a machine with

25,000,000 Eth birr. The coast doesn’t include the saving account which is given to

them by saving and credit association of Addis Ababa.

Activities Performed Through Kaizen

The first and second round activities have been implemented for DTAM and Ras Emiru through

Kaizen Systems. We did it basically with their own ------------.Now we are following their

activities and still the following activities has been performed:

Shape layout

Preparation of materials according to shop lay out

A decision was made on having a new tool store have been implemented.

Re-arrangement of raw materials.

Room partition.

Arrangement of Chair, table and Shelf.

Arranging raw materials in accordance with quantity and ---------

Seat arranged raw material in tool store.

Cleaning materials with comprador and Dicdel

Identifying problems of dysfunctional materials.

Room cleaning

Kaizen board.

Trashcan(Garbage)

Stick quotations in timber.

Training in auditing.

Benefits of Kaizen

The process of finding material takes 10-15 minutes before arrangement,

materials hidden and poor -------cleaning

Hidden materials found, creates conducive environment and time will be

saved.

Problem of installation will be solved.

After installation conducive, visible safe environment will be created.

The ware house re-arranged and all materials situated In a clear visible area.

Garbage prepared and situated in a specified area.

Expenditure for purchasing materials

Broom

Electrical materials such as Conduct breaker

Half kilo 5cm and 8cm nail purchased. The income was high after Kaizen

implemented because pieces of metal scrap sold.

Filling the gap by giving training such as filling, auditing management.

Sanitation undertake, first aid box a bounded plan pre pared. such plans

are:

Outcome which is planned monthly

Selling plan

Cash flow plan

Support given for those who need help

Concerning the enterprises implemented Kaizen continues follow-up support

Among the works in this year visiting, observing and assessing enterprises and

associations which implemented Kaizen such as Lalibella, Raccon, DETEMA wood and metal

enterprise. Accordingly:

4. Lalibella Wood and Metal Enterprise

Strangth: Place of the machine, organized office, cleanliness, their work flow is work

centered

Drawback: hand tool raw materials, Kaizen boards are twisted, misplaced in

unproperplace

Support: Give help, advice in order to arrange sitting materials in proper way.

5. Rlaccon Wood and metal enterprise

Strength: cleanliness

Drawback: Manufacturing wood and metals products together misusing flow of work (is

not work centered), no Kaizen board, unwillingness of accepting expertise advice and

support.

Support: give advice to --------working rooms, give expertise support such as cleanliness

of work place.

6. DTM wood and meals Enterprise

Strength: Organization using the office is better, Work flow and cleanliness of shade.

Draw back: Misuse of raw materials and improper placing of hand tools.

Support: give advice for placing raw materials and hand tool

Regarding of the training

Industry extension within 6 month of Kaizen implementation, short term training of women

and unemployed in entrepreneurship conducted with the cooperation of TVETs in the first,

second and third round. After training conducted the trainees were organized in association and

start operation .Trainees are:

In terms of first round training:

The aim was to train 500 unemployed trainees, but 402 of them were trained in different fields in

Entoto and Shro Meda Technical and Vocational College.

Measurement Plan Accomplishment in

%

People 500 402

80.4

Trainees Data in the First round

No. Training Field Male Female Total No.

1. Electricity 25 14 39

2. Ceramic 12 2 16

3. Sanitary 4 2 6

4. Block product 43 34 77

5. Food Preparation 11 43 54

6. Laundry 3 7 10

7. Chemical Process 2 8 10

8. Sewing 9 42 51

9. Wood Work 14 3 17

10. Metals 6 3 9

11. Leather 8 15 23

12. Authomechanic 7 3 10

13. Barbering and House hold 39 43 79

Total 189 213 402

Among the trainees of 402, 57 Male and 112 Female with a total number of 169 were embraced

in 11 associations.

The following table shows name of associations and field of occupations

NO. Name of Association Field of Occupation Male Female Total

1. Ertale Blocket 20 0 20

2. Unity Blocket 18 2 20

3. Entoto Blocket 11 9 20

4. Emmy Barbering Hair dressing 0 10 10

5. Aser Abebawoch Hair dressing 0 10 10

6. Fertuna Precast 8 2 10

7. Edeget Laundary 0 12 12

8. Edget Leather 0 17 17

9. Enchet Sera Wood Work 0 10 10

10. Fast Food Food Preparation 0 15 15

11. Food Preparation Food Preparation 0 25 25

Among the organized association three Blocket and Precast associations began production

with 37 Male and 13 Female and a total number of 50 members.

No Name of association Field of

occupation

Male Female Total

1. Unity Blocket 18 2 20

2. Entoto Blocket 11 9 20

3. Fertuna Precast 8 2 10

The plan was to train 165 Males and 135 Females with a total of 300 unemployed, but 164

trainees of which 96 Males and 68 Females gained the training.

Measurement Plan Accomplishment in

%

People 300 164 61

Details of the Trainee

No. Field of training Male Female Total

1. Blocket 42 37 79

2. Building 6 5 11

3. Ceramic 7 4 11

4. 11 6 17

5. Electricity 19 3 22

6. Wood work 7 3 10

7. Leather 8 10 18

8. Metal 15 0 15

9. Sewing 1 3 4

10. Sweather 3 3 6

Total 116 74 190

Among the trainees who have taken the training 3 associations were organized namely:

No. Name of

Associations

Field of

occupations

Male Female Total

1. Yenegew Tesfa Blocket 9 14 23

2. Zaf Electric

Instalation

12 0 12

3. Jantekel Blocket 9 15 24

Total 30 29 59

From second round trainees those good grade scorers are 51Males and 44 Females with a

total number of 95 peoples have got their job in different Enterprises.

No. Name of institutions Occupations Created

job

opportunit

ies

Male Female Total

1. Anbessa Shoes Leather 29 28 57

2. Ramsay Shoes Leather 10 16 26

3. B & C Allumium Metal 5 0 5

4. Detame Wood &Metal 5 0 5

5. Private Electric

Installation

2 0 2

Total 51 44 95

Third round training

Initially it was intended to train 115 Males and 85 Females with a total sum of 200 unemployed.

Out of these 97 Males & 79 Females totally 176 trainees took the training on different fields.

Measurement Plan Accomplishment in

%

People 200 176 88

Details of the Trainee

No. Field of training Male Female Total

1. Leather 8 35 43

2. Building 4 0 4

3. Ceramic 10 3 13

4. Wood work 13 7 20

5. Pipe 2 0 2

6. Metal 18 0 18

7. Blocket 27 33 60

8. Electric 15 1 16

Total 97 79 176

N.B. These do not include Entoto graduates.

Cobblestone Trainees who have got job.

No Field of Trainee Name of

associationation

Male Female Total

1. First round Tenker Cobblestone 11 0 11

2. Second round Hand to Hand

Cobblestone

15 8 23

3. Fourth round Natnael cobblestone

Kenenissa

cobblestone

Bonsa cobblestone

Kenenissa

cobblestone

15

18

18

18

3

0

0

0

18

18

18

18

4. Fifth round Semen cobblestone 56 0 56

5. Eighth round Yenegew Sew

cobblestone

Ras Michael

cobblestone

HaHu cobblestone

Sefera Genet

cobblestone

13

15

19

3

7

5

4

2

20

20

23

5

6. Ninth recruited 28 25 53

Total 234 54 288

The coordinators work leaders got private plan beside 1 to 5 plans and a check

list.Additionaly time is allocated for meetings to assess---------.During second round there was

no attitude gap in institution level because problems identified and solved in the first round

training. Training is conducted deliberately and trainees working privately, in factories and also

in associations.

Kaizen Workshop management, bussness plan, work ethics, leadership, resourse

management ------plan preparations credit and service, book keeping, market

competency ,trainings given by Vocational schools. The training conducted by two rounds. The

first training conducted in the first two days but the second round was wider and it takes 1 week.

The training was vital to fill the gap.

Regarding the input more or less there had been no shortage excluding Computer and table.

A ground plus 4 building is underway by world Vision .The operation was lagging behind due to

absence of Engineer, but now the contractor hired engineers and the building process is taking

place on a large scale. In addition to this the charity organization is willing to help organized

trainees. Namely:

5. Unity Blocket Enterprise Private Limited Company with 15 members.

6. Yenege tesfa Blocket Enterprise Private Limited Company with 23members.

7. Entoto Blocket Private Limited Company with 20 members.

8. Jantekel Blocket Private Limited Company with 20 members.

And the total number of these associations is 78.After they organized themselves in

associations they requested to be aided by the following materials;

Blocket production machine

Plastic pipe

Spade

Spoon for concrete mixing

Glove

Wok uniform

Timber

-----

------

-------

-------

This was presented for the charity organization with specification and they are waiting

for the purchase and delivery of the materials to begin their work.

In Shro Meda Training institution all the materials were purchased by World Vision.

For all departments machineries and accessories were purchased and the remaining is on process,

specifically for leather department many types of machinery were bought, but machineries for

shoe manufacture are not still purchased.

Document exploration

These reports were obtained from Entoto Polytechnic Cluster College for research purpose. The

main aims of this study was to investigating the problem happened before one year from this

document exploration you can easily identify how far wrong report mislead the top management.

One can also easily identify from this document unexpected work done by Kaizen teams the

report indicate that how far the Kaizen team did several things like additional space got during

implementation, production improvement and since the presentation was only focused orally on

the weakness parts of the newly employed workers as expressed on the case questionnaire.

The document investigation found that under the problem parts of the college document i.e. (A)

“Failure to actively involve newly selected members of the implementation group from the

college and woredas. (B) Unable to recruit qualified employees for the jobs.

Entoto Technical and Vocational Education and Training College

Ref. No. Et/C/4157/7/6

Date 7/5/04

Addis Ababa Technical and Vocational Education and Training Agency

Industrial Extension and Technology Transfer Main Job Process

Addis Ababa

Subject: Report of Support for Gulele sub city small and micro enterprises

Support given by Entoto Technical and Vocational Education and Training College in

collaboration with the agency to 12 selected small enterprises from Gulele sub city on:

Production quality and improvement

Technical Skill training

Job creation and management

Technology capacity building

The list of activities by the support group from Tahisas 16/2004 to Tere 4/2004 explained in 10

pages is attached to this letter.

Sincerely

Deans Office

CC

Industrial Extension and Technology Transformation Main

Industrial Extension Service main

Addis Ababa

Entoto Technical and Vocational Education and Training College Industrial Extension and

Technology Transformation Job Process implementation group identified the following

attitudinal, skill, resource limitations and corrective measures with their outcomes on the support

to 12 selected small and micro enterprises in Gulele sub city.

Operational fields of the12 selected enterprises

Metal works----------------2

Wood works----------------4

Construction----------------1

Food Preparation-----------5

Structure of the target enterprises

Association-----------------12 Enterprises

Group------------------------ None

Private-----------------------None

Reasons for selection

They are model enterprises

Feasible to give Cooperative Training For TVET trainees

132 employees participated in the 12 enterprises from which 45 of them are females

All have taken industrial extension service giving training

Table 13: List of the Model Enterprises of the name of selected enterprises locations fields of operations, structure and numbers of employs. Appendix 1 Table 13 Management practices data related to practice of Kaizen in the enterprises

Problems identified by the implementation group.

Lists of the modal enterprises List of the Model Enterprises

Problems identified by the implementation group

Attitudinal

Time management problem on entry and exit time

Failure in planning certain activities and inability to prepare necessary resources in advance

Members of the implementation group are new to the activities which leads to loss of confidence

Skill limitations

New members are not familiar with job Coordination problem during commencement Lack of a trainer for Tapestry training

Resource

Failure of the enterprise in providing the necessary resource at the right time which leads to delay and compromised quality

Unavailability of a training module prepared in Amharic language for the less educated trainees

Failure to give trainings based on resource plans Unavailability of a professional level document for tapestry training Failure to provide safety garments and other equipment

Problems identified from the enterprise

Attitudinal

Failure in providing the necessary resource at the right time Failure of employees to take trainings and make it business as usual Reluctant to disclose their income and expenses Unable to work according to the established system Being absent from work for different reasons

Skill

Limitation in preparing business plan, business management and procurement management

Limitation in accounting knowledge and unwilling to hire a professional Limitation in the skill of machinery handling and protection Lack of skill in the various machinery operating techniques Limitation of knowledge in galvanic collision

Resources

Poor quality machineries, lost their safety parts Unavailability of safety materials (dust proofs, helmets, uniforms) Scarcity of tools

Sanitation problem

Problems from the coordinating party

Limited number of trainers Corrective suggestions which are not based on supervision Failure to actively involve newly selected members of the implementation group from the

college and woredas Unable to recruit qualified employees for the jobs

Activities performed to solve the problems from the implementation group

Attitudinal Reached agreement with all members on punctuality by trying to avoid the factors

affecting time management, using other possible options in cases of transportation problems

With a relentless effort from the implementation group, the problems are evaluated and solved

Skills They are made to observe experienced implementation group members and work

accordingly It is programmed in to prepare plans in advance and assess daily activities to solve

the problem of coordination

Solutions from the implementation group

Resources A training on business planning and management is given on the work sites with

available resources where all equipment and machineries are not fulfilled In association with other trainers, previous training manuals are found, a new

Amharic training module is prepared and the training is given Despite the fact there is no professional level for Tapestry, better methods for

efficient use of resources for the work is suggested

Solutions from the implementation group

Attempts to fill gaps by establishing a system in which informed parties let know others Training are conducted with the use of available resources in trying to make it

standardizedSolutions for the problems from the enterprise

Attitudinal

Creating awareness on the scope of support to avoid dependency, getting material support from the college for which the enterprises pay and convincing them to own easily available materials.

Trainings are given to the less active employees and they are made aware of their roles

Trainings are given that change their attitude and enable them establish a consistent working system

Skill Necessary resources are gathered to fill the gap of skills based on the given

professional standards Business management and machinery operation trainings are given

Trainings are given on the association’s work site

Metal works and assembly technique trainings are given in workshops

Resources

Some machineries are maintained with capacity of the implementation group and safety panels are produced

Some of the enterprises are using uniform workshop garments while processing to purchase other safety tools

Outcomes

With regard to productivity increment Unlike before, workshops and machineries are organized in a structural way to

ease production Leaving a conducive working space suitable for proper production Some dark workshops using electricity convert their roofs to transparent roof

sheets which enables them to save electric power Ventilating the workshops and made them conducive work environments Waste storage bins are prepared to keep workshops clean and shop sanitation

trainings are given

Entrepreneurship and skill development trainings

Business plan preparation trainings are given and members are made to prepare their own business plans

Entrepreneurship trainings are given Accounting training is given

Technical skills training

In relation to wood works, personal and machinery safety trainings are given Wood work training is given In relation to metal works, trainings on galvanic collision and parameters affecting

galvanic collision are given

Technological capacity building

With regard to technological support, a portable chair imported from Indonesia is disassembled, designed and made from local pieces of woods which decreases the cost of the chair which is been introduced to enterprises.

Outcomes for each enterprise

1. Kidist Mariyam wood works Shop width 150 m2

Extra space which obtained after implementation 30 m2

Expense for implementation 500 ETB Income from by-products (scrap) 300 ETB Support of Electric installation in ETB 1000

2. Ralkon Metals and woods Shop width 200 m2

Extra space 60 m2

Expense for implementation 500 ETB Income from Waste 3000 ETB Support of Electric installation in ETB 1000

3. Addis Kidan Construction Shop width 200 m2

Extra space 60 m2

Expense for implementation 1500 ETB Income from Waste 500 ETB Support of Electric installation in ETB 1000

4. Nib Household and Office furniture Shop width 200 m2

Extra space 60 m2

Expense for implementation 1500 ETB Income from Waste 300 ETB Support of Electric installation in ETB 1000

5. Lalibela wood works

Shop width 140 m2

Extra space 50 m2

Expense for implementation 1500 ETB Income from Waste 1000 ETB Support of Electric installation in ETB 800

6. AbroAdegMetals and woods Shop width 180 m2

Extra space 60 m2

Expense for implementation 1500 ETB Income from Waste 200 ETB Support of Electric installation in ETB 150

7. Addis MerafPacked Foods Shop width 150 m2

Extra space 45 m2

Expense for implementation 50 ETB

8. KimshaPacked Foods Shop width 150 m2

Extra space 45 m2

Expense for implementation 50 ETB

9. TesfalakalGudateghochPacked Foods Shop width 180 m2

Extra space 50 m2

Expense for implementation 1000 ETB Support of Electric installation in ETB 2500

10. Harina Packed Foods Shop width 90 m2

Extra space 30 m2

Expense for implementation 800 ETB Support of Electric installation in ETB 2000

11. Godana Shop width 180 m2

Extra space 90 m2

Expense for implementation 50 ETB

12. AmbagerPacked Foods

Shop width 200 m2

Extra space 80 m2

Expense for implementation 2500 ETB Income from Waste Support of Electric installation in ETB 3000.