Post on 31-Aug-2014
Training Session
5 Son
Part 1 - What is 5 S&
Part 2 - How to Implement 5 S
Part 1 - What is 5 S
Now, we will see !
QUALITYQUALITY
SAFETYSAFETY
EFFICIENCYEFFICIENCY
CONTROLCONTROL
Customer Satisfaction
Employee Satisfaction
Equipment
Material
Jigs/Tools
Method
Workers
Products
Timeliness
Maintains
Ensure Max. Utilization
UpkeepsImproves
Motivates
Ensures Good
Promotes
Impact of 5 S at the Workplace
INDIA
U. S. A.
JAPAN
1950 1960 1970 1980
•Seiri - Sorting
•Seiton - Systematic Arrangement
•Seiso - Cleaning
•Seiketsu - Standardization
•Shitsuke - Training & Discipline
What are the 5 S?
What is
We Will See First ….!
SEIRI(SORTING)
Seiri - Sorting
SEIRI - SORTING /REORGANISATION
To clearly devide objects in to two groups
•Those items that are necessary.
•And Those items that are not necessary.
•To get rid of the unnecessary and to keep the necessary.
Seiri - Sorting
WHAT IS UNNECESSARY
• Item is not needed.
•Item is needed however, quantity in stock is more than what is needed for consumption in near future
•Contingency Parts : Critically decide the quantity of contingency parts to be retained and criteria for such parts.
Seiri - Sorting OrganisationFrequency of use Storage Method•Things you have not used Throw them out in the last one year.•Things you have used once Store at distance OR in the last 6-12 months. Keep in store•Things you have used only Store it in central once in the last 2-6 months. place in your zone.•Things used more than once Store it in the central a month. place in your zone•Things used once a week Store near the
workplace.Things used daily or hourly Store near the
workplace.
LOW
AVER
AGE
HIGH
Seiri - Sorting Organisation
Identifying unnecessary1) Parts and Work in Process (WIP)•Things fallen back behind the machine or rolled under it.•Broken item inside the machine•Things under the rack/platforms.•Extra WIP•Stock of rejected items•Items accumulated over period for rework•Material awaiting disposal decision•Material brought for some trail, still lying even after trail•Small qty of material no longer in use Cont…..
Seiri - Sorting Organisation
Identifying unnecessary2) Tools, Toolings, Measuring devices•Old jigs, tools not in use lying.•Modified tools, tooling for trial, are lying after trail.•Worn out items like bushes, liners, toggles etc. lying.•Broken tolls, bits etc. may be lying.•Measuring equipment not required for the operation being performed, is lying.
3) Contingency parts•Many times storage place for contingency parts become a last refuge for broken parts, surplus items and things nobody is likely to use. Cont…..
Seiri - Sorting Organisation
Identifying unnecessary4) Shelves and LockersShelves and lockers tends to collect things that nobody ever uses, like surplus, broken items etc.
5) Passage and Corners :Dust material not required seem to gather in corner.
6) Besides Pillars and under the stairs:These place tends to collect junk, spittoon etc.
7) Walls and Bulletin BoardsOld out dated notices which have lost their relevancePosters or bulletins on wallDust, remain on torn notices, cell tape pieces Cont…..
Seiri - Sorting Organisation
Identifying unnecessary8) Floor, Pits, PartitionsDefective partsProtection caps, coversPacking materialHardware items, small itemsEven tools,small itemsEven tools, tooloingItems dropped on the floor are never picked
9) Computer Hard Disk•Many unwanted, outdated, temporary files pile up
Cont…..
Seiri - Sorting Dealing with papers
How to reduce papers on your table?
1) Make a single pile of papers
2) Go through them and sort in following categories :a) Immediate actionb) Low priorityc) Pendingd) Reading materiale)For information
Seiri - Sorting Dealing with papers
How to reduce papers on your table?4D principle
DO... DELEGATE….
DELAY….DUMP….
What is
Now,We Will the Second one ...!
SEITON(SYSTEMATIC ARRANGEMENT)
Seiton - Systematic Arrangement
SEITONA Place for Everything And...
Everything in its Place …!
Seiton - Systematic Arrangement
How to achieve Systematic Arrangement?
•Decide where things belong•Decide how things should be put away•Obey the ‘Put away’ rules
Seiton - Systematic Arrangement
How to achieve Systematic Arrangement?• Decide where things belong - Standardize Nomenclature - Determine an analytical method for storage• Decide how things should be put away - Name & location to everything. Label both item and location - Store material functionally - Prevent mistake with coding by shapes & colour
contd….
Seiton - Systematic Arrangement
How to achieve Systematic Arrangement?
• Decide how things should be put away - Follow ‘first in first out’ rule - If two identical items are to be located, then store them separately, colour code them.• Obey the rules - Put the things back to their location after their use
Seiton - Systematic Arrangement
How to achieve Systematic Arrangement?
USE:1) Signboard
2) Colour codes
3) Outline marking
4) Labels
Seiton - Systematic Arrangement
Functional Storage
Seiton - Systematic Arrangement
Functional Storage
Usage * Store frequently used material Frequency near the workplace and
less frequently at some distance
Weight & * Heavy material should be storedShape of at lower levels/layersthe Material Place directly on the material
handling device for case of handling
Seiton - Systematic Arrangement
Functional StorageCategory * Same category of material may
be stored in one location. Eg. Allen Screws, Oil Seals
Operation * All items required for an Wise operation may be stored in one
location. Eg. Allen key, spanner etc. hand
tools required for setting m/c
Seiton - Systematic Arrangement
Functional Storage• Outlining and Placement Marks
-Marks boundaries of dept. aisles, Machines-Follows straight line, right angle rule-Nothing shall be kept outside the boundaries
• Stand and shelves-Keep only required number of stands and shelves -Standardize height, size-Provide casters where necessary so that it can be move
Seiton - Systematic ArrangementFunctional Storage• Wires and Ducts - Colour code - When there are multiple connections – bundle the wires, label them and lake sure that they are in straight line / right angle and firmly anchored
• Machine -tools & Tools - Put the tools in the order you need them - Location of the tools should be such that it can be put away with one hand - Try to eliminate some hand tools by permanently attaching it to the bolt head
Seiton - Systematic ArrangementFunctional Storage• Blades, Dies other important consumables
- Stores them in the protected place- Maintain these things regularly by applying rust preventive, oiling etc.
• WIP – Work In Process- Designate a place for each component / part- Decide on how much quantity to be stored- Ensure that there is no damage to good part during transit, they do not get rusty and they are not mislabeled.
Seiton - Systematic ArrangementFunctional Storage• Oils
- Reduce number of oils used (Standardize)- Colour code for oil- Safety aspects – fire prevention, pollution, leak, spillage
• Instrumentation & Measuring Devices- Label them, show direction of flow
That is
Now,We Will the Third ...!
SEISO( CLEANING )
Seiso - Cleaning
SEISOClean workplace completely so
that, there is no dust on the floor, machines and equipments …!
Seiso - Cleaning
Activity - Keep workplace spotlessly clean- Inspection while cleaning
- Finding minor problems with cleaning
inspection
Success - Reduction in machine down time
Indicator - Reduction in no. of accidents
Seiso - Cleaning
While cleaning up and getting rid of dirt and unclear items potential defects such as Abrasion, Damage, Loose Parts, Deformities, Leaks, Vibration, Abnormal Sound etc., are revealed and hence Seiso is inspection
Seiso - Cleaning
• Here cleaning means more than just keeping things clean. Cleaning should be viewed as a form of Visual Inspection•Preventive measures should be taken to tackle problems of dust, grim, burrs, leakage etc. Roots cause of the problem should be identified and it should be eliminate
Seiso - Cleaning
5 Minutes Every day for cleaning
•Devote 5 minutes every day for cleaning your work area •Participation of everyone is required •Attack hard to clean places regularly
Seiso - Cleaning
Cleaning - Inspection Points for most equipmentTightening Loose bolts, welding detachment,
loose parts, vibration or bumping noise, friction
Heat Oil tanks, motors, heaters, axles, control panels, washing/cleaning water, bearing, wiring etc.
Seiso - Cleaning
Cleaning - Inspection Points for most equipment Breakage, Breakage, cracks dent on sliding Cracks parts, handle has come off,
broken switches, wire joints come off, wires are broken orcrack dial of various pre, gauge,meters etc.
Now, Fourth ‘S’ is ...!
SEIKETSU( STANDARDISATION )
Seiketsu - Sandardisation
SEIKETSUSetting up Standards / Norms for a neat & clean workplace and details
of how to maintain the Norms(Procedure) ...
Seiketsu - Sandardisation
Maintain & ImproveThe Standard of :
SeiriSeitonSeiso
Seiketsu - Sandardisation
•Regularizing 5S activities so that abnormalities are revealed.•Make it easy for everyone to identify the state of normal or abnormal condition
•For maintaining previous 3 S, deploy visual management
Seiketsu - Sandardisation Visual Management
•It has been estimated by scientific study that 60% of all human activities starts with sight•5S is easy to do once. It is consistency that is difficult. That is why Visual Management is so important, so that evreybody will know that there is some problem.
Seiketsu - Sandardisation Visual Management
What visual controls communicates?
It grabs one or more of our senses in order to
Alert us to an abnormalityHelp us recover quicklyPromote adherence and preventionEnable successful self management
Seiketsu - Sandardisation Visual Management
Some method for visual communication :Colour codingUse of LabelsDanger AlertsIndication where things should be putDirectional arrows/ marksTransparent coversPerformance indicators
Seiketsu - Sandardisation Visual Management
Some method for visual communication :
Labels:Precision management labelsInspection LabelsTemperature LabelsResponsibility labels
Seiketsu - Sandardisation Visual Management
Points to remember in making visual control tools :
1) Make them easy to see from distance2) Put the display on the things3) Everyone can tell what is right and what is wrong4) Anybody can follow them and make necessary corrections easily5) Work place should look brighter & orderly
Seiketsu - Sandardisation Visual Management
Some everyday visual management example :
Traffic signalZebra crossingIn car - Petrol indicator
- Speed IndicatorDirection arrowsElectric danger sign etc.
Seiketsu - Sandardisation Visual Management
Some visual communication signs :
And, Fifth ‘S’ is ...!
SHITSUKE(TRAINING & DISCIPLINE)
Shitsuke - Training and Discipline
We need everyone to maintain 5S guidelines.
To maintain DISCIPLINE, we need to practice and repeat until it becomes a way of life.
Discipline is the Core of 5S
Shitsuke - Training and Discipline
Discipline means making a steady habit of properly maintaining correct procedures.
Time and effort involved in establishing proper arrangement and orderliness will be in vain if we do not have discipline to maintain it.
Shitsuke - Training and Discipline
PledgeIt shall be my constant effort to maintain my workplace in good order by
Assign a place for everything & keeping everything in its placeSorting out unwanted material periodically and discarding themKeeping my work area neat & clean everyday
Part 2
How To Implement 5S
How To Implement 5S
Step 1
Form a 5S CommitteeOR
5S Coordicator
How To Implement 5S
Step 2
Divide the Workplace
into various Zones
How To Implement 5S5S format 1 Zone at ‘work’
Group Area Type of Audit Line/ Section Zone No.
How To Implement 5S
Step 3
Allocate Zones to the relevant people
How To Implement 5S
Step 4
Start ImplementingSeiriSeitonSeiso
How To Implement 5S
Step 5
Audit the 5SImplementation Process
How To Implement 5S5S format 25S Audit Calendar For the month of :
S. No. Name Area of Audit Type of Audit Zone Dates
How To Implement 5S5S format 3 5S AUDIT CHECKLIST – SUPPORT GROUP
5S Points Mark Range Marks1. SEIRI (SORTING)a) ITEMS/PROCESS MATL/INSTRUMENTS SORTED & IDENTIFIED AS 1-10 OK, Usable immediately Usable (Spares) Good, Not Required Rework Scrapb) FILES AND RECORDS SORTED AND IDENTIFIED AS 1-5 Current/Follow up Not Required (to be sent to Record Room)c) ANY ITEM /FILES/RECORDS LYING UNSORTED 1-5
SUB-TOTAL2. SEITON (SYSTEMATIC ARRANGEMENT)a) Table, Chairs, Cupboards, Racks & Bins Neatly Arranged 1-5b) Items neatly arranged and identified as Under process/Spares/Scrap 1-5c) Arrangement of files in Filing Rack 1-5d) Any items /files lying haphazard 0 or 5
SUB-TOTAL3. SEISO (Cleanliness)a) Tables, Chairs, Machines 1-5b) Surroundings Area free of oil, chips, cotton waste etc. 1-5c) Floor, wall, (Including Glass of Windows & Ventilation) Ceiling (Tube Light, Fans & Roof) 1-5d) Measures taken to consume electricity 1-5
SUB TOTAL TOTAL
Signature of Zone Member Sign of Auditor Date Name Dept
How To Implement 5S5S format 4 5S AUDIT CHECKLIST – PRODUCTION GROUP
5S Points Mark Range Marks1. SEIRI (SORTING)a) ITEMS/PROCESS MATL/INSTRUMENTS SORTED & IDENTIFIED AS 1-10 OK, Usable immediately Usable (Spares) Good, Not Required Rework Scrapb) FILES AND RECORDS SORTED AND IDENTIFIED AS 1-5 Current/Follow up Not Required (to be sent to Record Room)c) ANY ITEM /FILES/RECORDS LYING UNSORTED 1-5
SUB-TOTAL2. SEITON (SYSTEMATIC ARRANGEMENT)a) Table, Chairs, Cupboards, Racks & Bins Neatly Arranged 1-5b) Items neatly arranged and identified as Under process/Spares/Scrap 1-5c) Arrangement of files in Filing Rack 1-5d) Any items /files lying haphazard 0 or 5
SUB-TOTAL3. SEISO (Cleanliness)a) Tables, Chairs, Machines 1-5b) Surroundings Area free of oil, chips, cotton waste etc. 1-5c) Floor, wall, (Including Glass of Windows & Ventilation) Ceiling (Tube Light, Fans & Roof) 1-5d) Measures taken to consume electricity 1-5
SUB TOTAL TOTAL
Signature of Zone Member Sign of Auditor Date Name Dept
How To Implement 5S5S format 5 5S AUDIT CHECKLIST – ADMINISTRATIVE GROUP
5S Points Mark Range Marks1. SEIRI (SORTING)a) Records, files with clear Labeling 1-10b) Memos / Letters Sorted out for Filling/ Action/ Follow-up 1-5c) Any Items/Files/Records lying unsorted 0 or 5
SUB-TOTAL
2. SEITON (Systematic Arrangement)a) Work Table, Chairs and Personal Belongings 1-5b) Layout of office & office equipment (filling cabinet, Waste Paper Bins, Computers & Stationary 1-10c) Any items/ Files Lying Haphazard 0 or 5
SUB TOTAL
3. SEISO (Cleanliness)a) Tables, Chairs, Computers 1-5b) Cupboard, Filing Cabinet 1-5c) Floor, wall, (Including Glass panes of Windows & Ventilators) Ceiling (Tube Light, Fans & Roof) 1-5d) Measures taken to consume electricity 1-5
SUB TOTAL TOTAL
Signature of Zone Member Sign of Auditor Date Name Dept
How To Implement 5S
5 S NOTICE BOARD 1 AREA PROBLEMS FOR GROUP 5S ASSESMENT CHART
DATE
2 ZONE
3 LEADER TODAY TODAY LAST MONYH AVERAGE AVERAGE
SEIRI
4 PARTICIPANT SEITON
SEISO
TOTAL
How To Implement 5S
Step 6 Give Recognition to best 5 S Team
Thank You