5S module
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Transcript of 5S module
5STRAINING
MODULE STRUCTURESession Duration
1. Session 01 - Importance of Target and Our Vision 15 Minutes
2. Session 02 - An Over-view of 5S 15 Minutes
3. Session 03 - 1S - SEIRI 30 Minutes
4. Session 04 - Genba Exercise (1S Master list) 15 Minutes
5. Session 05 - Genba Exercise (1S Master list-Distinguish) 15 Minutes
6. Session 06 - 2S - SEITON (Examples) 30 Minutes
7. Session 07 - 2S - Genba Exercise 30 Minutes
8. Session 08 - 3S - SEISO 15 Minutes
9. Session 09 - 3S - Check sheet 15 Minutes
10. Session 10 - 4S - SEIKETSU 15 Minutes
11. Session 11 - 5S - SHITSHUKE 15 Minutes
12. Session 12 – SUMMARY 5S 30 Minutes
MODULE DURATION : 04 HOURS
SESSION 1Importance of Target and Our Vision
DURATION : 15 MINUTES
Nothing is impossible……………..
IF YOU WORK WITHOUT TARGETS, IT WILL BE LIKE…
WITHOUT A LIGHT HOUSE
WITHOUT WICKETS
CRICKET
SHIP
IF WE DON’T FIX TARGET, WE DON’T KNOW WHERE WE HAVE TO GO
MOVING TOWARDS
CRICKET
WITH
WICKETS
SHIP LIGHT HOUSE
IF YOU WORK WITH TARGETS, IT WILL BE LIKE…
FIX THE TARGETFIX THE TARGET
BE CLEAR ABOUT YOUR TARGET
EVERYTIME WE FIX HIGHER TARGET, WE WILL STRETCH OURSELF AND
PERFORM BETTER
TARGET
TARGET STOPS US FROM DOING UNPRODUCTIVE JOBS
TARGET PREPARES US TO GO AHEAD TO REACH THE SET GOAL
TARGET GIVES US A GREEN SIGNAL IF WE ARE ON THE RIGHT PATH
What is important to construct a strong building ?
Strong, Good
Foundation
is the basic criteria to construct
a rigid structure !
What is our Company’s vision ?
Building Infrastructure
Globally
Is the foundation
What is 5S ?What is 5S ?
NEXT SESSION
SESSION 2An Over-view of 5S
DURATION : 15 MINUTES
1S-SEIRI 2S-SEITON
3S-SEISO4S-SEIKETSU
5S-SHITSHUKE
ETPL
5S5S
Visual Factory • “Ability to understand the status of a production area
in 5 minutes or less by simple observation without use of computers or speaking to anyone.”
Objectives of 5S
3. PRODUCTIVE WORK PLACE
1. VISUAL WORKPLACE
2. SAFE WORKPLACE
4. STANDARDISED WORK PLACE
5. PLEASANT WORK PLACE
What we do on BHOGI festival ?
•Segregate unwanted things.•Keep it away.•Burn / throw out.
Why ?
But what about our working area ?
Abnormalities
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
In the following pictures, identify some of the” Abnormalities”
Tomo Sugiyama’s wisdom
People leave trash. People tolerate it. No one step to
pick up.
Tomo Sugiyama’s wisdom
People leave trash , some do not tolerate it , pick it up
Tomo Sugiyama’s wisdom
People do not leave trash , people do not tolerate it ,
Everyone picks it
SESSION 31S - SEIRI
DURATION : 30 MINUTES
How to get first level?
MR.DOUBT
Key 1: Seiri (Sorting)
Distinguish Between What Is Needed And Is Not Needed
Distinguish Between What Is Needed And Is Not Needed
Before starting 1S,
Let me tell you a story…
I am the goddess who give you all the below things. Who am I ?
I am the goddess who give you all the below things. Who am I ?
I am the goddess of
good fortune & wealth .
I am the goddess who gives you all the below things. Who am I ?
I am the goddess who gives you all the below things. Who am I ?
I am the goddess who gives you all the below things. Who am I ?
I am the goddess of poverty &
odium
Once upon a time…..
Both the goddess had a competition of who is
beautiful among them and they went to Narada for
judgment
Narada, tell me who is beautiful
among us ?
You both are You both are
equally beautiful…..equally beautiful…..
Lakshmi, you are beautiful Lakshmi, you are beautiful
when you when you ENTERENTER & Moodevi, & Moodevi,
you are beautiful when you you are beautiful when you
EXITEXIT
Good things are beautiful
when they enter and bad things when they exit
Good things are beautiful
when they enter and bad things when they exit
Theme
Now what do you want ?
Good things to enter
Or
Bad things to enter
To receive Lakshmi to our house/ factory / anywhere , what should we do ?
HOW TO DO 1S?
NEXT SESSION
SESSION 4GENBA EXERCISE (1S MASTER LIST)
DURATION : 15 MINUTES
MR.DOUBT
HOW TO DO 1S?
GIVE ONE- ONE IDEA
ALWAYS KEEP IN MIND-
DO WHAT YOU DOCUMENT,
DOCUMENT WHAT YOU DO
AGAIN GIVE ONE ONE IDEA- HOW CAN 1S BE DONE WITH
DOCUMENTS
NEXT SESSIONGENBA EXERCISE
(1S MASTER LIST – DISTINGUISH)
SESSION 5GENBA EXERCISE
(1S MASTER LIST-DISTINGUISH)
DURATION : 15 MINUTES
Read 1S List…One by One
Now…. Let’s go to Shop floor… & Distinguish Necessary &
Unnecessary Items…
TIME LIMIT : 10 MINUTES
Share the Learning…One by One
Height of housekeeping Height of housekeeping
MR.DOUBT
Where to keep the unnecessary items?
• • Temporary storageTemporary storage
• • Local holding areaLocal holding area
• • High VisibilityHigh Visibility
• • Holding area managerHolding area manager
• • Timely clearingTimely clearing
Red Tag Holding Area
WHAT IS 2S?
NEXT SESSION
SESSION 62S - SEITON
DURATION : 30 MINUTES
WHAT IS 2S?
Key 2: Seiton (Systematic Arrangement)
For Storing any items, following seven points For Storing any items, following seven points should be Considered :should be Considered :
1. Search Free
2. Count Free
3. Air Free
4. Climb Free
5. Bend Free
6. First in First Out
7. Heavy things on Lower Shelves
8. Store should be lighted & ventilated properly.
4 Good Signs of 2S
1. LOCATION : Outline, Arrows, Separators
2. IDENTITY : Description - “What is it?”
3. QUANTITY : How many should be here
4. INSTRUCTION : What do you want me to do?
4 Good Signs of 2S
1. LOCATION : Outline, Arrows, Separators
2. IDENTITY : Description - “What is it?”
3. QUANTITY : How many should be here
4. INSTRUCTION : What do you want me to do?
MR.DOUBT
STILL I AM NOT CLEAR ABOUT 2S?
Bolts
4 Pallets
1000x43 - SPECIFY QUANTITY
Bolts
1 - PROVIDE LOCATION
2 - PROVIDE IDENTIFICATION / NAME BOARD
3 - PROVIDE INSTRUCTIONS
4 Pallets
1000x4
Bolts
Delivery Time: 9.00 AMDaily
Let us see some Examples…
Team Member Area Information Board
1st Shift 2nd Shift
All Shift Communication Board
Production Graphs
Team MemberTraining Log
Sheets
Run TimeLog Sheet
Moulder SetupSheets
MaintenanceRequest Forms
Maintenance Repair Log
(Team MemberMaintained)
(Team MemberMaintained)
Tool and WIP BoardTo Be
Ordered
In Process
Next Run
Spec Card
Maintenance Log&
Maintenance Request Forms
Clean-up / WIP BoardTo be Ordered
In Process
Next Run
PreventativeMaintenance
Schedule Calendar
Organize & Demand the Maintenance of Tools
Everything has a Dedicated Home
Seiton workplace example..
VCS provided for component storage
Inserts / tools stored in bins with VCS
Seiton workplace example..
5S
Point of use tools in Mill Room What is needed, in reach, ready for use
Now…. Let’s go to Shop floor… &
Identify Location for Necessary Items…
TIME LIMIT : 20 MINUTES
Share the Learning…One by One
WHAT NEXT?
NEXT SESSION
3S
SESSION 83S – SEISO
DURATION : 15 MINUTES
Key 3: Seiso (Cleanliness)
“Cleaning Is Inspection"
• Eliminating all forms of dirt
• Finding ways to keep the workplace clean
• Adopting cleaning as a form of inspection
• Making cleaning part of everyday work
What is the army man standing in front of before going for war ?
Am I smart
Shine Concept…
• Clean to Inspect
• Inspect to Detect
• Detect to Correct
• Correct to Perfect
WHAT NEXT?
NEXT SESSION
3S – CHECKSHEET
SESSION 93S – CHECK SHEET
DURATION : 15 MINUTES
WHAT NEXT?
NEXT SESSION
4S
SESSION 104S – SEIKETSU
DURATION : 15 MINUTES
Maintain and monitor the first three KeysMaintain and monitor the first three Keys
Key 4: Seiketsu (Standardize)
• • CheckCheck• • StandardizeStandardize• • MaintainMaintain• • MonitorMonitor• • ImproveImprove
SESSION 115S – SHITSHUKE
DURATION : 15 MINUTES
Key 5: Shitshuke (Self-Discipline)
“SAY WHAT WE DODO WHAT WE SAY"
Shitshuke (Self-Discipline)
• Correct procedures are habitual
• Workers are properly trained
• Everyone has adopted Visual Factory
• The workplace is well
ordered according to agreed
upon procedures
• Managers are committed to
the 5 Keys as a way of doing
business.
PROPER TRAINING
CORRECT PROCEDURES BECOME A HABIT
SUSTAIN
MANAGERS COMMITTED
TO 5-S
5 Sasdfsdfssdfsdfdsfsdfsdfsfdsdfsdf
PARTICIPATION FROM ALL
EMPLOYEES
19
• Summary
– Cleaning serves many functions, including exposing abnormal and pre-failure conditions and building pride in the workplace
– Unless changes in work activities are standardized, things will go back to the way they were before improvement
– The Five Keys should be implemented on an ongoing basis, and should involve everyone
– Location Maps facilitate implementation
Keys 3, 4, 5: Shine, Standardize, Sustain
Reduces search time Eliminates defects Improves product quality Improves cost effectiveness Improves communication Eliminates work frustrations and delays Increases workplace safety Increases job satisfaction among workers
Benefits of Visual Factory System
. . .And, In Conclusion• Workplace Organization and Standardization begins with Project Identification and includes five keys:• Sort, Stabilize, Shine, Standardize and Sustain
• Red Tagging is a tool for Sorting
• Location Maps & Indicators are used in Stabilizing
Who Gets Most Benefited by 5S?
My Society
MyCompany
MyHouse
5S
Employees should adhere
Obedience
Discipline
Full – hearted approach towards given goal
5S
SESSION 125S – SUMMARY
DURATION : 30 MINUTES
1-11-2
1-31-4
2-12-2
2-32-4
‚R-‚P3-2
3-3
3-4
4-14-2
4-3
4-4
5-15-2
5-35-4
2-2
1S-SEIRI 2S-SEITON
3S-SEISO4S-SEIKETSU
5S-SHITSHUKE
RULE
A place for Everything,Everything in it’s place
Cleaning is Inspection
Standardization
Self-DisciplineSorting Out
5S Photo Display ( Fixed Point Photo )
Before After
Our Factory Environment…(Generally)
After Sorting...
1S
After Systematic Arrangement..
2S
After Cleaning...
3S
After Standardising...
4S
Building the Discipline…
5S
In a village there lived an saint old man who was kind hearted,
illiterate and a very good foreteller. Whatever he used to
foretell was final and everyone in the village used to go to him
even for little problems. They treated him next to god.
Morale
In the same village there lived an educated man. He was
quite egoistic and never liked the faith people had in that
saint. One day, he planned to make the saint feel ashamed.
As usual, All village people assembled for Saint’s Speech in
the morning. Educated man also joined the crowd. Suddenly,
He said, ”Saint!! In my hand, a small Dove is there. Can u tell
me the fate of this bird? If this bird is going to be dead or shall
remain alive!! Educated man thought if saint tells that the bird
shall remain alive, I’ll kill the bird and if he tells that the bird is
going to be dead, I shall release the bird..
What would have Saint replied..??
The bird live or die is in your hands
Like same story
Our Company 5S Implementation is in our hands only!!!!