5S Improvement
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Transcript of 5S Improvement
Lean Manufacturing
PRESENT BY : PRAVIN N
PRAJAPATI
Lean Manufacturing..
"lean” is a systematic method for the elimination of waste within a manufacturing system.
Simply Lean Means.. Creating more value for customer with fewer resources.
The Ultimate goal is to provide perfect value to customer through a perfect value creation process that has zero waste.
List of lean tool…. 5S Andon Bottleneck Analysis Continuous Flow Gemba (The Real Place) Heijunka (Level Scheduling) Hoshin Kanri (Policy Deployment) Jidoka (Autonomation) Just-In-Time (JIT) Kaizen (Continuous Improvement) Kanban (Pull System) KPIs (Key Performance Indicators) Muda (Waste)
Overall Equipment Effectiveness (OEE) PDCA (Plan, Do, Check, Act) Poka-Yoke (Error Proofing) Root Cause Analysis Single-Minute Exchange of Dies (SMED) Six Big Losses SMART Goals Standardized Work Takt Time Total Productive Maintenance (TPM) Value Stream Mapping Visual Factory
Types of Waste or Muda
1. Overproduction2. Inventory3. Waiting4. Motion 5. Transportation6. Defects7. Over processing
Reason for implement 5S
Improved Safety - No item on floor - Safety device in their right place - Less dust - Better overview
Reason for implement 5S
Improved Safety Fewer breakdown - less dust from dust or grit in moving part. - fewer error
Reason for implement 5S
Improved Safety Fewer breakdown Better work environment - A clean work place - Fix unsafe work place
Reason for implement 5S
Improved Safety Fewer breakdown Better work environment Fewer human error - Small but anything fault are fixed - It should be easier to do right
Reason for implement 5S
Improved Safety Fewer breakdown Better work environment Fewer human error May find problem earlier - when you clean a machine you inspect at same time
Reason for implement 5S
Improved Safety Fewer breakdown Better work environment Fewer human error May find problem earlier No Searching - Effective tools at the right place
Indirect gains with 5S
Practical training in lean for leaders & Workers.
Better impression in global market.
Easier to recruit good people.
What is 5S ?
The purpose of 5S is to promote a safe & efficient work environment 5S is a method that uses five Japanese word which start with “S” Seiri – Sorting Seiton – Set in order Seiso – Shining (Clean) Seiketsu – Standardize Shitsuke – Sustain
Procedure…
1S : Sorting
Sorting has two main purpose - Remove unnecessary objects - Reduce waste
Go through the whole plant - Machine & Control centre - Works area - Storage and common area
1S : Sorting
Remove unnecessary objects
Look for.. Material - Behind or under machine - Rejected - “Forgotten” material
1S : Sorting
Remove unnecessary objects
Look for.. Material Tool - Not in use - Worn out / Broken
1S : Sorting
Remove unnecessary objects
Look for.. Material Tool Spare parts - Broken - Surplus inventory - Spare part for machine no longer in use
1S : Sorting
Remove unnecessary objects
Look for.. Material Tool Spare parts Out of date document - Files - Manuals - Computer temp. file Other Stuff
Red tag for 5S
2S : Set in Order
Arrange and mark the location of the all objects Organize remaining items
2S : Set in order -- PlacementItem
Very rarely use Long intervals between use
Frequently use
Can be placed outside Work room Placed Near the Machine Place closer to user location
Floor Marking
Agree on a colour code Visualize
Work Surface Safety Zones Machine Surface Transport surface
3S : Seiso – Shine (Clean) Clean the workspace and all equipment,
and keep it clean tidy and organized.
At the end of each shift, clean the work area and be sure everything is restored to its place.
Identify and eliminate causes of dirt and grime – remove the need to clean
Carry out regular cleanliness inspections.
4S : Seiketsu - Standardize
Simplify the way of maintaining cleanliness.
Develop procedures, schedules, practices.
Continue to assess the use and disposal of items.
All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station.
4S : Seiketsu - Standardize
Try to eliminate the problem.
Implement daily routines
Implement weekly procedure
Use a planning system
Planning Boards
5S : Shitsuke - Sustain
To maintain 5S, we need the discipline to practice and repeat until 5S become a way of life.
Visualization Board This is our area This is how it should look This is how we take care of our area. This is how we want to improve our area. This is how we make sure that the routines are being followed.
5S : Shitsuke - Sustain
Audits :Schedule regular audits Ex.:
Each Week – Team leader Each Month - Supervisor Every two month – Higher management
Thank You