Total Quality Management - Spring 2010 - IUG1 Total Quality Management Week # 11 5S Prepared by:...

Total Quality Management - Spring 2010 - IUG 1

Total Quality ManagementTotal Quality Management

Week # 11Week # 11

5S5S

Prepared by: Khalid DahleezPrepared by: Khalid Dahleez

Faculty of Commerce – the Islamic Faculty of Commerce – the Islamic University of GazaUniversity of Gaza

This material was collected from different sourcesThis material was collected from different sources


WHAT IS 5S? IN ORDER TO ACHIEVE HIGH LEVELS OF

QUALITY, SAFETY,AND PRODUCTIVITY, WORKERS MUST HAVE A CONDUCIVE WORKING ENVIRONMENT

Developed by the Japanese Housekeeping System Helps Create a Better Working Environment

and a Consistently High Quality Process


What is 5S? An easy definition is: Finding a place for

everything and putting everything in its place. 5S is also the foundation for Continual Improvement

(CI) and Lean implementation.

It’s a mindset & commitment to achieve a totally waste-free operation that’s focused on your customer’s success… achieved by simplifying and continuously improving all processes

It’s the elimination of waste Everywhere – while adding customer value…


1. Sei-ri (Organization)2. Sei-ton (Neatness)3. Sei-so (Cleaning)4. Sei-ke-tsu (Standardization)5. Shi-tsu-ke (Self-discipline)

5S ONCSS

5S stands for 5 initials of the following Japanese words:

3


THE 5S PRINCIPLES

SEIRI – Organisation/Sort out

SEITON – Orderliness/Systemize

SEISO – The Cleaning/Shining

SEIKETSU – STANDARDIZE

SHITSUKE - Sustain/Discipline


DISCOVERY OF 5S

Thirty years ago researchers started studying the secret of success of Japanese manufacturing companies

5S turned out to be the most impressive "secret"

The factories were so well organized that abnormal situations were readily apparent

Equipments were so clean and well maintained that any problem such as a loose bolt or leaking oil could be easily seen

This passion of cleanliness and orderliness became a hallmark of Japanese organizations


• Dictionary definition: To put things in order (or organize them) according to a specific rule or principle.

• Industrial definition: To distinguish between necessary things and unnecessary things, and getting rid of what you do not need.

Seiri = Organization (SORT)

means we remove all items from the workplace that are not needed for current production (parts, tools, equipment, etc).


1. ORGANISATION(SEIRI)

Decide what you need Remove unnecessary clutter All tools, gauges, materials, classified and

then stored Remove items which are broken, unusable

or only occasionally used Key Words:

1. Classification management (Necessary & unnecessary things)

2. Red tag movement3. For unnecessary things, find their true

causes.


Why is my desk gettingWhy is my desk getting messy? messy?

Necessary UnnecessaryNot necessary

now, but maybe in the future

Every item on my desk belongs to the gray circle


Do you throw these things away?

It works!

It has a value!

It’s still new!

It’s usable!

It looks nice!

Not necessary now, but maybe

in the future


RED TAG TECHNIQUE

GIVE STAFF RED LABELS ASK STAFF TO GO THROUGH EVERY

ITEM IN THE WORK PLACE ASK IF NEEDED & THOSE THAT ARE

NEEDED,IN WHAT QUANTITY NOT NEEDED (RED TAG IT ) STORE IN THE RED TAG AREA

RED TAG


For wavering items

PLACE THE SUSPECTED ITEMS IN THE RED TAG AREA FOR ONE WEEK

ALLOW THE STAFF TO REEVALUATE THE NEEDED ITEMS

AT THE END OF WEEK THOSE WHO NEED ITEMS SHOULD BE RETURNED

REDTAG


1. Eliminate defects and breakage

2. Organize the warehouse

Before AfterT. Sugiyama “The 5S Approach to Improvement” PHP, 1995

Typical Seiri Activities


Dictionary definition: Establishing a neat layout so that you can always get just as much of what you need when you need it.

Industrial definition: It is a way of eliminating search.

Seiton = Neatness - Orderliness - Set in Order

ONCE YOU HAVE ELIMINATED ALL THE UNNEEDED ITEMS

NOW TURN TO THE LEFT OVER ITEMS


How long is your patience?5 minutes? 2 minutes??

or5 seconds???

Question When you ask someone to bring a hammer, how long can you wait without getting mad?

Organise layout of tools and equipment:1.Designated locations2.Use tapes and labels 3.Ensure everything is available as it is needed and

at the “point of use”


30 Second Rule

Workplace Checkpoints:-1. Positions of aisles and

storage places clearly marked?

2. Tools classified and stored by frequency of use?

3. Pallets stacked correctly?4. Safety equipment easily

accessible?5. Floors in good condition?


Key Words:Design an efficient layout (Functional storage)Eliminate search (Less search)Everything should have a name.(A place for everything and everything in its place)

Typical Seiton Activities:Stripes on filesFirst in, first outEasy to read notices

Key Words & Typical Activities


3. SEISO (CLEAN/SHINE) Create a spotless workplace Identify and eliminate causes of dirt and grime –

remove the need to clean Sweep, dust, polish and paint

Definition: Eliminating trash, filth, and foreign matters for a cleaner workplace. Cleaning as a form of inspection.

• SHINE means we sweep floors, scrub machines, apply a fresh coat of paint, and then we KEEP it that way. This way, everything will be in top working condition so that it may be used when it is needed.

• It also means preventive maintenance.


Keep things clean + Inspection (Caring attitude)

Key Words:

1. Divide areas into zones2. Define responsibilities for cleaning3. Tools and equipment must be owned by

an individual4. Focus on removing the need to clean


Sanitation engineers

Laundry

Dry cleaner

Janitor

Garbage collector

Pollution control operator

Clean-room designer

One-third (1/3) or one-fourth (1/4) of the total investment amount is used for cleanliness.

Cleanliness is a big business today.


4. SEIKETSU (STANDARDISE)

Generate a maintenance system for the first three

Develop procedures, schedules, practices Continue to assess the use and disposal of

items Regularly audit using checklists and

measures of housekeeping Real challenge is to keep it clean


Definition:Keeping things organized, neat, and clean, even in personal and environment aspects.

Seiketsu = Standardization

SEIRI SEITON

SEISO


Ideal State Current State

GAP

Seiketsu = Standardization

1.Define an ideal state2.Standardize the solution (5S standardization)


1. Make quality manual2. Directional markings3. Color-coded pipes

Typical Seiketsu Activities

• STANDARDIZATION happens when the first three S’s are properly implemented and maintained.

• It means that racking, paint colors, labeling, operational layouts are designed in a standard fashion.

• Everything will be in place so everyone will know exactly what they are responsible for; and, exactly when, where, and, how to do it.


5. SHITSUKE (SUSTAIN / DISCIPLINE)

Means inoculate courtesy & good habits Driving force behind all 5S Deming’s point number 1: Constancy of

purpose Make it a way of life Part of health and safety Involve the whole workforce* Develop and keep good habits


Definition:Doing the right things as a matter of course.

Shitsuke = Self-discipline

We SORT areas. We SET IN ORDER work places. We SHINE areas. With STANDARDIZATION it is easy to identify anything out of place.

SUSTAIN is different: It isn’t a single separate activity; We SUSTAIN when we have developed habits of always using the first 4 S’s together on a daily basis.


1. Habit formation (Make it a habit)2. Create a disciplined workplace

Key Words & Typical Activities

1. Wear your safety shoes2. Exercise time3. No smoking at workplace

Typical Shitsuke Activities


WHAT U HAVE COME ACROSS

Followings can be harnessed form the 5S1. NEAT & CLEAN WORKPLACE2. SMOOTH WORKING3. NO OBSTRUCTION4. SAFETY INCREASES5. PRODUCTIVITY IMPROVES6. QUALITY IMPROVES7. WASTAGE DECREASE8. MACHINE MAINTENANCE9. VISUAL CONTROL SYSTEM10. EMPLOYEES MOTIVATED11. WORKSTATIONS BECOME SPACIOUS


SortClear out rarely usedItems by Red Tagging

StraightenOrganize and Label aPlace for Everything

ShineClean ItStandardise

Create Rules to Sustainthe first 3 5’S

SustainUse Regular ManagementAudits to Stay Disciplined Eliminate

Waste

5 S’s


When Does 5S Happen?

ALL THE TIME!! 5S is a mindset and a culture. The 5S’s are a part of each Associate’s workday. There will also be CI Events and WPO (WorkPlace Organization) Events. In an Event, Associates are taught how to implement the principles of Continual Improvement.


How is 5S Implemented? By the associates! Who has a better idea

to make our jobs easier than us? Our management is committed to improving how we work.

We want to work smarter, not harder. Along the way, support will come from EVERYONE.

We will teach the 5S process, and together we will implement it and make it work.


ADVANTAGES OF 5S If tools and materials are conveniently located in

uncluttered work areas

Operators spend less time looking for items This leads to higher workstation efficiency, a

fundamental goal in mass production

A clean and tidy workplace leads to greater well being

and increased motivation

Company image improves


ADVANTAGES OF 5S Health and Safety is ensured Machine maintenance Quality Productivity Lean Manufacturing TIME SAVING QUICK RETRIEVAL ACCIDENTS & MISTAKES MINIMIZED INCREASES SPACE CREATES WORKPLACE OWNERSHIP


ADVANTAGES OF 5S RESULTS IN A PLACE EASIER TO MANAGE SMOOTH WORKING NO OBSTRUCTION NO DEVIATION, NO PROBLEMS

B/C EVERYONE KNOWS WHERE THE THINGS ARE SPPOSEDF TO BE


ADVANTAGES OF 5S FOUNDATION OF ALL QC TOOLS

CONTINUOUS QUALITY IMPROVEMENT LEAN MANUFACTURING KINDERGARTEN OF QUALITY TOOLS &

TECHNIQUES


ADVANTAGES OF 5S VISUAL MANAGEMENT SYSTEM

VISUAL CONTROL TO SEE THE ABNORMALITIES

SIMPLE SIGNALS THAT PROVIDE AN UNDERSTANDING OF THE CONDITION( NORMAL/ ABNORMAL)

A LOOK AT THE PROCESS REVEALS ITS DIRECTION (RIGHT/WRONG)

Total Quality Management - Spring 2010 - IUG1 Total Quality Management Week # 11 5S Prepared by:...

Documents

Transcript of Total Quality Management - Spring 2010 - IUG1 Total Quality Management Week # 11 5S Prepared by:...