5S Implementation -A Snapshot

8/12/2019 5S Implementation -A Snapshot

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Confederation of Indian IndustryCII-AVANTHA Centre for Competitiveness for SMEs1 20 February 2007

Confederation of Indian Industry


CIIAVANTHA Centre for Competitiveness


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Confederation of Indian IndustryCII-AVANTHA Centre for Competitiveness for SMEs2

5 S

( Work Place Improvement )

Implementation & Monitoringof


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5S is a basic, fundamental,

systematic approach for

productivity, quality and safetyimprovement in all types of

business.


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Who will Benefit by 5S

Any type of business, from a retail store to a power plant

-- from hospitals to television stations - all types of

businesses, and all areas within a business, will realize

benefits from implementing a Five S program.


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What will it cost me?

Improved Profitability

Efficiency Service

Safety


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CII-AVANTHA Centre for Competitiveness for SMEs7

Sort

Set in Order

Shine

Standardise

Sustain

Seiri

Seiton

Seiso

Seiketsu

Shitsuke

Elements of

5 S


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ObjectiveTo bring a cultural change in the

organization...

.Achieve through

Total Employee Involvement.


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1Sorting out :

Sort &OutWhat to Sort & What to

sendOut (REMOVE) ?


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1Sorting out :Sorting:

Identify,Segregate

Wanted & Unwanted things


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CII-AVANTHA Centre for Competitiveness for SMEs 11

ORGANIZATION CHART FOR '5S' TEAM

CEO

5S' COMITTEE

COORDINATOR

DEPUTYCOORDINATOR

ZONE-1 ZONE-2 ZONE-3 ZONE-4 ZONE-5 ZONE-6 ZONE-7

TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER

TEAM

MEMEBERS

TEAM

MEMEBERS

TEAM

MEMEBERS

TEAM

MEMEBERS

TEAM

MEMEBERS

TEAM

MEMEBERS

TEAM

MEMEBERS

1Sorting out :Team members

are operators


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A Five S program is usually a part of, and the

key component of Visual Factory and

(Workplace) Management. And 5S and VFM

are both a part of Kaizen -- a system of

continual improvement -- which is a

component of lean manufacturing.


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Make zones by allocating a reasonable area to each leader


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RED TAG :-A Card containing detailed

information of unwanted things

with a given time limit for

further action to be taken.

To be used based on following

questions:

What is required ?

How much is required ?

When is it required ?

Where is it required?

Section / Area :-

Name of Item : Quantity :

Reason :-

1. Obsolete 5. Unnecessary

2. Defective 6. Mix - up

3. Scrap 7. Unidentified

4. Not in place 8. Others

Action :-

1. Move to Scrap Yard 4. Rectify

2. Locate properly 5. Return to Supplier

3.Segregate 6. Others

Target date of disposition:

Remarks :-

1Sorting out :5 S RED TAG


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CII-AVANTHA Centre for Competitiveness for SMEs15 Confederation of Indian IndustryCII-L M Thapar Centre for Competitiveness

Removing Red Tagged stuff

What Stuff would you Red Tag in these pictures ?

Think Break


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1 Sorting out

REDTAG AREA

Removal of unwanted things


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Methodology to Implement 1S: ( Contd.)Fix a date and time for Red Tag Campaign& carry out theaudit across all Zones.

Search & Identify unwanted things and tie them with a REDTAG.Other than product scrap, Red Tagged items should bemoved to respective RED TAG AREA.

All those items which are finally identified unwanted ones

should be reviewed by the review committee and decision

for disposing off should be taken within a fixed time(

MaximumTime Limit is 15 days).

1Sorting out :


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Zonal Leader & Members Photos

Photo

Current month view

Date : 11.01.08 Date :11.01.08

ZONAL MEMBERSZONAL LEADER: MR. ANAND KUMAR

ZONE: 2


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CII-AVANTHA Centre for Competitiveness for SMEs 20

RED TAG CAMPAIGN


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RED TAG CAMPAIGN

Unused Raw Material due

to excess Inventory.

Created Free Space.


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RED TAG TARGETS

Types of items

Red-tag

targets

Physical areas

Inventory

Equipment

Floors, walkways, operation areas,

well, shelves, warehouses

Raw materials, procured

parts, processing parts, in-

process inventory, assemblyparts, semifinished products,

finished products

Machines, equipment, Jigs,

Tools, cutting bits, gauges, dies,

carts, conveyance tools,worktables, cabinets, desks,

chairs, supplies

Identifying Red-Tag Targets

1S


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DISPATCH DEPARTMENT

BEFORE AFTER

RACKS TO BE

REMOVED

Rack Removal

6x8 feet space released


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Example of 1 S

Before AfterHabit of accumulating unwanted things


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Example of 1Sat Office Area

Before After


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CII-AVANTHA Centre for Competitiveness for SMEs

BEFORE

FTER

B f Af


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Before After

HP LP

Waterpump

House

Fly Ash

Silo

Operation Panel


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NO LEAKAGE

AFTER

BEFORE

BALCO POWER PALNT


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2S

Systematic

Arrangement


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Objective

Place for Every Useful Thing & Every Useful Thing is

on itsplace .

Arranging them in a Systematic manner.

Result: Reduces Search Time

(Systematic Arrangement)2S


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SEITON is important because it helps eliminatemany kinds of waste in the workplace

Motion WastePerson sent to find cart searchedfull factory

Searching WasteNo one can find the key to

the tool cabinet

Waste of Human EnergyFrustrated workergives up searching for template after two hours

2S


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Waste of Excess InventoryDesk drawers arefull of papers and stationary supplies

Waste of defective productsItems not kept

back in the same location so worker picks up

wrong piece for assembly

Waste of unsafe conditionBoxes of material

kept in the walkway, causing someone to trip

and get injured

2S


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Steps to do SEITON

Step ADeciding Appropriate location1.Principles of Storing jigs, tools, dies to eliminate

waste

2.Principles of motion economy to eliminate waste

3.5 S Map to decide location

Step BIdentifying location

1.Signboard Strategy

2.Painting Strategy3.Colour coding Strategy

4.Outlining strategy

Step 2 - SEITON2S


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Methodology to Implement 2SCheck What(Item Identification)?, Where( Location)?

& How Much( Quantity)? When( Time limit)? Before

actually practicing 2S.Decide appropriate location for every thing.

Display identification mark for every location.

Items stored should have the Identification Mark includingpurpose of storage & its review date.



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Direction for Respective Departments, Shops, Reception,

Canteen , Visitor Rooms, Meeting Halls . is clearly

marked and displayed.

Direction for Toilets and Water Coolers is self informative.

Display boards are available for Safety / Fire Prone Areas.

Display of Speed Control of the vehicle inside the factory

premises is adequate.

(Systematic Arrangement)

Presence of Good 2SContd..

2S


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Direction for Dispensary is clearly marked & displayed.

Serial numbers on Fans , Machines, Tube Lights, .are

present & visible.

Important / emergency Telephone Numbers are displayed

at appropriate locations.

Instructions for Safety / Quality Standards are clearly

visible.

Shadow Boards are available at the appropriate locations.

(Systematic Arrangement)

Presence of Good 2S( Contd.)

2S


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Benefits of 2S

Faster retrieval of things, result in Elimination ofSearch Time.

Opportunity to correct the abnormalitiesfaster as

visibility improves by system itself.Space Savingby systematic arrangements.

Efficiency of work improves as things are available

when they are actually needed.



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Kaizen No. 1

Kaizen Theme:Easy identification of pipeline

Problem: There was no

identification on the pipeline with

respect to the pump

Benifits:

Reduction of time for identifying the

pipeline with respect to pump.

0

5

10

15

20

25

30

35

Before After

Time in minMin


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Right Things in the Right Place.

2S


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Before

After

(Systematic Arrangements)

Pre-Fixed

Locations

2S


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Shadow Boards2S

Only shadows on board .. Empty boardShadow board with tools


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Kaizen 3

Zone no:2


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Kaizen 3Zone No.2BOILER

ThemeCOLOUR CODING OF ALL

PRESSURE GAUGES IN MILL AREA

ProblemEARLIER THERE WAS NOCOLOR-CODING OF PRESSURE GAUGES

IN MILL AREA.OPERATORS ARE NOT

ABLE TO PREDICT THE SAFE WORKING

CONDITION OF THE RUNNING

EQUIPMENTS.NOW COLOUR CODING OF

96 NOS,. OF GAUGES HAVE BEEN DONE

Benefits

IDENTIFICATION TIME REDUCED.

SAFE WORKING RANGE OF HYD. PUMP WAS

PREDICTED RESULTING IN LESS FAILURE.

Costof Implementing : RS.10/- PERGAUGE.

Zone no:2

BEFORE

AFTER


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BALCO POWER PLANT

Identification

of thevalve ON-OFF

position


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EASY IDENTIFICATION

BALCO POWER PLANT


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Kaizen No. 1

Kaizen Theme:Easy inspection of water pr. gauge

Problem: Pressure gauge was at 25

mtr height .The pressure has to

check twice in a shift.

Benifits:

Movement reduced.

CPP-1/zone-4sz-5

Before

After50

00

10

20

30

40

50

60

Before After

2 S


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Example of 2S at office area2S


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Solution / Benefit:

All the Pipe Lines were labeled, it

help the operators to operate in

safer atmosphere and it also

reduce time of operation

Problem:

Earlier, Pipe Lines were notlabeled due to which operation

was not understood

Kaizen No. 5

Kaizen Theme: LABELING OF PIPES

Benefits -


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Benefit:

It help local operator in proper

identification which save time.

(5 mins approx.)

Problem:

Earlier there was no properindication of pneumatic valve

open or close

Kaizen No. 1

Kaizen Theme: Valve open and close visual indication.

C D

3 S


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3 S CLEANLINESS)

ShineEverything


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3 S


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Objectives and Benefits of Practicing3S

Provides dust free environment.

Creates safe & healthy work place.

Ensures higher quality of work & products.

Increases the efficiency & life of equipment .

Improves Visibility to identify abnormalities.

3 S Shine everything )


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7 types of

Abnormalities

Unfulfilledbasic

conditions

Inaccessibleplaces

Unsafe places

Unnecessaryand Non-

urgent items

Quality defectsources

Contaminatedsources

Minor Flaws

7 Types of Abnormalities

3 S


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Example of 3Sat Shop Floor

3 S Shine everything )


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Before

After

BHARAT ALUMINIUM COMPANY LIMITED


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Problems:

View before thermography showing a

header looks externally well insulated,with no Thermal Loss

If survey done through IR gun gives

satisfactory result

Solution: Oil stand, color coding of oil drums& Equipments, Oil measuring can

Kaizen Theme: Finding abnormalities through Thermography

Before

A

F

T

E

R

Costof Implementing : Nil

Benefits

The maximum observed temperature

is very high.

The loss on evaluation = 0.04

KCal/kWhr (Approx)

Revenue loss = 5000 Rs PA

Thermography shows the hot spot at various

locations

BALCOKaizen No.1 Kaizen at Turbine area


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Solution / Benefit:

Gives visual identification of location of

leakage

Loss in terms of heat & cost is known

Creates awareness of the employeeGives the commitment towards work.

Problem:

Earlier leakages were noted down inthe defect lists, also the losses in

term heat & cost were not

evaluated.

Kaizen Theme:To create awareness about the leakages with proper quantification

-(Harshal Ambulkar)


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5S Implementation -A Snapshot

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