Poka-YokeZero Defects Manufacturing

5’S’ Program on Work place Organization &

Standardization

An Ancient Prayer

From the cowardice,

That Makes us,

Shrink from the Truth ;

From the laxness,

That Keeps us ,

Content with Half Truth ;

From the Arrogance,

That Makes us Believe,

That We know All truth ;

O’ My Lord,

Deliver Us.

How Adults Learn & Retain…

• 20% of what they hear

• 30% of what they see

• 50% of what they hear and see +

• 70% of what they hear, see and say

+ +

• 90% of what they hear, see, say and do

+ + +

Type of presentation Ability to recall after 3 hours

Ability to recall after 3 days

Verbal (one-way)

lecture

25% 10-20%

Written (reading) 72% 10%

Visual and verbal

(illustrated lecture)

80% 65%

Participatory

(role plays, case studies)

90% 70%

Learning Recall

But First...Death by Initiative

This is NOT a new initiative!

A NewWay ofDoing

Business!

It is NOT a new way of doing business!

It is merely doing what we alreadydo, but doing it BETTER!

Join the Run

5 ‘S’ is ComingJoin The Run

What is 5’S’ ? A basic, fundamental, systematic approach for productivity, quality and safety improvement in all types of businesses.

The Five S program focuses on having visual order, organization, cleanliness and standardization. The results you can expect from a Five S program are: improved profitability, efficiency, service and safety.

The precipices underlying a Five S program at first appear to be simple, obvious common sense. And they are. But until the advent of Five S programs many businesses ignored these basic principles.

What is 1’S’ ? This is step 1 in a Five S program:

"Sorting" means to sort through everything in each work area. Keep only what is necessary. Materials, tools, equipment and supplies that are not frequently used should be moved to a separate, common storage area. Items that are not used should be discarded. Avoid keeping things around just because they might be used, someday.

Sorting is the first step in making a work area tidy. It makes it easier to find the things you need and frees up additional space. The Principle involved is Sort In – Sort Out .

Mixed items - Before Sorting Items arranged - After Sorting

Tools placed - After Sorting

Plug pins placed - After Sorting

Pins & screws placed - After Sorting

All Tools,pins,screws, are lying – before Sorting

Sorting : Remove the Unneeded items, Rearrange /Regroup the Needed Items as per Predefined Categories

Sort In - Sort Out

1 ‘S’ – Sort

How is 1’S’ carried

out ?

Keep the wanted things & remove the unwanted things using Red Tag Procedure .

Red Tags Procedure : Red Tags Procedure :

Red Tag Procedure is first step of sort activity. All items at the work place are critically analysed for their use & availability at work place. All unneeded items & those in excess of their normal use are removed to a remote area marked as Red Tag Holding Area. The idea of this activity is to keep only those items in that area which are relevant & required in relevant quantities. All items shifted to red tag area carry a red tag which is filled with, quantity, reason for red tag, tagged by, date of tagging, reason for tagging disposal proposal & action by, review date & status of disposal.

Item Name:

Quantity:

Reason for red tag

Identified by:

Date:

Reason1.Obsolete2.Not needed now (once/year)3. Not reqd in the qty stored4.Not reqd in that area5.Defective/ scrap6.Use not knownDisposal1.Discard2.Return3.Sell4.Move to separate storage area5.ReworkDisposalActionBy:DateReview/ DisposedRed-tag file no.

1’S’ Each tag is allotted a unique S. No. Also there is an action plan updated with every addition to red tag area to ensure that items don’t lie there indefinitely, but are disposed at appropriate times.

Area Map :Area Map :

Area map is the second step of Sort activity. Area map shows location of equipments ,racks for material storage & flow of materials. Different colours are used to show the movement of different kinds of materials. From plan it can be easily seen the distances of travel with help in relocation for improved layouts using principles of flow & minimum distances.

VISUAL INSPECTION AREA

G A N G W A Y

Gangway of PA AREA

G A

N G

W

A Y

TABLE

STAND

RACK RACK RACK RACK RACK RACK RACK RACK RACK

std.

I/P Rack

PAV3

RACKRACKRACKRACKRACKRACKRACK

I/P RACK I/P RACK

A L/C-1

A L/C - 4

IMAGE-1

IMAGE-2

TAMPO

AL/C-2

PAD3

OVEN RACK RACK RACK RACK RACK

PAV4 PAV2

PAV5 PAV1 PAV6

TABLE

R

Panel Panel

PanelPanelPanel

I/P RACK

Pr Pr Pr

Pr Pr

O/PO/P

O/PO/PI/P RACK

O/P

From WashingDesignations / Signs :Arrow lines Flow of Material

EMPTY BI

N

S

Cupboard for solvent/and other things

RACK

RACKRACKRACK

A L/C-1

A L/C - 4

O/P

PAV2

PAV6

TABLE

Panel

Panel

Pr

Pr

O/P

I/P Rack

What are benefits of 1’S’ ?

When should be 1’S’ activity started ?

Creation of space is single biggest advantage of 1’S’

Generally if you are facing problem of lack of space, go for 1’S’ & space problem is eliminated.

Sometimes one gets surprised with the amount of space released as a result of 1’S’ activity.

The other advantage is money released due to sale of unwanted items lying unattended for long times.

1’S’ Being the first the step of 5’S’ program should be starting point.

Where is 1’S’ useful ?

What are the success indicators of 1’S’?

1’S’ is useful in factories work areas , offices & homes alike.

Housewives find it maximum useful. Even Municipal corporations are getting their staff trained in steps of 5’S’ as they realize immense benefits of it.

The space generated & money released are the success

indicators.

Seiri – Sorting Out

SEIRI

Unnecessaryitems

Necessary items

How often do youneed them?

Is disposalexpensive?

Resale value?

Immediatethrow-away

Seldom but can'tthrow away

Sometimes

Always

Storage location

Action

Minimize cost ofdisposal

Try to sell

Throw awayquickly

Separate

A little far away

Close

What is 2’S’ ? 2s stands for Set in order

The Principle involved is ’Place for everything & Everything in place’

When is 2’S’ Activity started?

2’S’ Activity is started immediately after 1’S’. This sequence has to be followed strictly.

How is 2’S’ activity carried

out ?

2’S’ activity is carried out making use of lines , labels & signages.

Lines Standard For Floor Lines Standard color & widths are used for marking locations

Type ColourWidth(Inch)

Notes Illustration

Aisles (area divider) lines Yellow 3” Solid

Door Range Lines Yellow 2” Broken

Entrance/Exit Arrows Yellow 2” Solid

Direction Arrow Yellow 2” Solid

Place Marks for Dustbins Red 2” Broken

Place Markers for Material (WIP)

Green 2” Solid

Place Marks for Racks, Cupboards, Work tables

Yellow 2”Corner Line4” long

Place Marks for defective materials

Red 3” Solid

Caution AreaYellow & Black (STRIPES)

2” Alternate solid

Place Marks For Safety Equipment

Red 2” Solid

Seiton – Set In Order

SET IN ORDER

TOOLS/GUAGES

items

INPUT/OUTPUT MTLSM

Is it close at hand?

Is the area marked ?

Is the items labeled? labeled

Does it follow storage freedom ?

Is the area marked?

Storage location

Storage location

On a template

As per operation requirement

Six freedom rules

Defect fact cards 3W1E cards

On floor or stand

Is the rejects area marked separately?

Is the matl Identified?

On floor or stand

Is the limits set? Is the limits set? As per prodn req

Labels

Signages

Labels of standard fonts & sizes are used to mark locations, equipments,bins & containers.

Fire extinguishers, exit ways are marked using standard symbols.

What is benefit of 2’S’ ?

Time for searching tools , items files etc is eliminated to zero.

Before After

What is 3’S’?

3’S’ Stands for shine.

The principle involved is ‘cleaning with meaning’

Cleaning methods should address questions like what is being cleaned, where is it being cleaned, how is it being cleaned, who will clean & when will it be done.

The cleaning schedule should include walls, floor, roof etc.

Locations for cleaning material must be marked & 2s for cleaning material should not be ignored.

Abnormalities like loose wires, leakages must be tagged promptly.

Cleanliness is also helpful to notice damages on equipment such as leaks, breakage and misalignment.

SCRAP CARRIER

Seiso- Shine

SHINE

MATERIALS

items

CALENDAR

Is it close at hand?

Is the area marked ?

Is the items labeled? labeled

Recording with meaning ?

Is the method clear

Cleaning Check list

Storage location

In a stand

As per operation req

Tags/Register

Daily/weekly

As per the area

Who is to clean?

Is what to clean identified?

On floor or wall

Is the limits set? Is the frequency set As per process req

What are the benefits of 3’S’ activity?

How is 3’S’

activity done?

3’S provides safe, imaculate & pleasant surroundings.

It is very important to boost the morale of working people

Clean thoroughly the workplace inside out. Roofs, Equipments , floor.

Start from the top & come down

gradually.

3’S’ Prepare the cleaning check-lists & follow them.

S.No

What When How Who

1 Floor Cleaning

Shift Start & EndWhenever there is spillage.

Floor Mops Brooms

Sweeper & certified by SIC

2 Machine cleaning

Shift Start & EndWhenever there is spillage.

Waste Cloth & Solvent

MC Operator

3 Wall Cleaning from Dust & Cobwebs

1st Day of Month

Brooms with extended handles

Sweeper & certified by SIC

4 Work Tables

Shift Start & EndWhenever there is spillage.

Waste Cloth & Solvent

M/C Operator

What is 4’S’? 4’S’ stands for standardization of 1’S’, 2’S’ & 3’S’.

The Principle involved is standardisation of above 3s i.e. defining clearly what is required level to be achieved.

The workplace must have display of required standards. Area map. Audit sheets, work instructions,Do’s & Don’ts in that workplace.history cards for equipments, COT checklists, Safety check lists, production performance graphs, Quality performance graphs, planned maintenance records, OEE graphs, improvement tracking graphs.

When is 4’S’ carried out?

4’S’ is carried out after completing 3’S’ activity.

It is important to follow the sequence as bypassing the steps can lead to no benefit of any step.

The idea is workplace should speak itself giving an idea about state of affairs in the

shop.

Seiketsu - Standardise

Prepare a list of all standards that needs to be located in the work area

this will include, area map, 5 S audit sheet

PICTORIAL WORK INSTRUCTIONS FOR-OPERATION & DO'S and DONT'SSMED, AM-COT, SAFETY POINTS

HISTORY CARDPLANNED MAINTENANCE-RECORD AND PLANSCURRENT PERFORMANCE GRAPHS/TRENDS-

PRODUCTION INFORMATION AS OF CURRENTOUTPUT PERFORMANCEQUALITY PERFORMANCE

OEEIMPROVEMENT'S TRACKING GRAPHS/CHARTS

SKILL LEVELANY OTHER INFO THAT MAY BE REQUIRED FROM TIME TO TIME

Audit both the area and equipment for all the above work instructions and usage- no ncr's

Prepare Audit sheets and conduct audits

4‘S’ – StandardizeWorkplace Organization Checklist for: ______________________________Score 5: No non-conformances

Score 3: Upto 2 non-conformances

Score 1: More than 2 non-conformances

5 3 1Seiri>Sort Distinguish between what is needed and not needed

Organisation Have all unnecessary items been removed?

Are all remaining items neatly arranged?

Are walkways / aisles and work areas clearly outlined?

Does a procedure exist for removing unneeded items?

Seiton> Set In order A place for everything and everything in place

Orderliness Is there a place for everything?

Is everything in its place? (Search free, count & climb free, FIFO)

Is it easy to find out where to keep items?

Are things put away after use?

Is the standard quantity for each item established?

Seiso>Shine Cleaning and looking for ways to keep it clean and organized

Cleanliness Are work areas clean and hygenic?

Is equipment kept clean?

Are cleaning materials easily accessible?

Are all items kept in the demarcated places?

Are cleaning guidelines and schedules easily visible?

Are Seiri (sort) and Seiton (stabilize) complete?

Seiketsu>StandardiseMaintain and monitor the first 3 categories

Adherence Is all necessary information (locations, machine names etc.) visible?

Are all standards (e.g. colour code, label etc.) known and visible?

Is there a checklist in the area?

Are standards and limits (of storage) easily recognizable?

Shitsuke>Sustain Stick to the rules

Self-Discipline Does everyone observe the standard procedure?

Are red tags procedures followed?

Are personal items and belongings stored neatly?

Are job aids up to date and effective?

Miscellaneous

Total for each score

Over all total

Percentage score (divide by 115)

Process Owner:______________________________

Category Particulars to be checkedScore given:

Score 5: No non-conformances Record ofScore 3: Upto 2 non-conformances scoring

Score 1: More than 2 non-conformances

Non-conformances observed:

Date

Average

Sel

f-sc

ore

Sco

re g

iven

by

5-S

team

What is 5’S’ activity ?

5’S’ stab\nds for sustain.

Sustain activity is carried out using following steps :

Train all operators in observing SOPs & Red Tag Procedures.

Place of neat storage of personal items.

Process owners carry out Daily Audit & 5’S’

Teams meet once a week.

Recognition for Best Area as a rolling trophy.

How is 5’S’ activity done ?

Sustaining is done through Audits & Training

Act on Audit Nonconformities

5 ‘S’ Sustain

S.No. Action Who Target Date

Action Plan