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MN 4001

Assignment No1

2013106 AD1
Indravarman Rajeswaran

CONTENTS
1.
2.
3.
4.
5.
6.
7.

Introduction
Plan-Do-Check-Act Approach to 5S

Five S ..
Applications of 5S
..
5S in the workplace .
The 5 pillars of a visual workplace .
The role of storage in the 5S workplace organization

methodology
8. Conclusion
9. Reference

.. .

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4
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Introduction
5S is one of the most widely adopted techniques from the lean manufacturing
toolbox. Along with Standard Work and Total Productive Maintenance, 5S is
considered a "foundational" lean concept, as it establishes the operational
stability required for making and sustaining continuous improvements.
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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

The primary objective of 5S is to create a clean, orderly environment- an


environment where there is a place for everything and everything is in its
place. Beyond this, many companies begin their lean transformation with 5S
because it exposes some of the most visible examples of waste it also helps
establish the framework and discipline required to successfully pursue other
continuous improvement initiatives.
The 5S program focuses on:

having visual order

organization

cleanliness

standardization

The results you can expect from a 5S program are: improved profitability,
efficiency, service and safety.
The principles underlying a 5S program at first appear to be simple, obvious
common sense. And they are. But until the advent of 5S programs many
businesses ignored these basic principles.
5S was developed in Japan and stands for the Japanese words seiri (tidiness),
seiton (orderliness), seiso (cleanliness), seiketsu (standardization), and
shitsuke (discipline). These words have been adopted to English to maintain
"5S."

Plan-Do-Check-Act Approach to 5S
The PDCA (plan, do, check, act), or Deming cycle, of implementing 5S is
effective. This is a never-ending process and has to follow a process approach.
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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

Five S
S1-Sort
Sort refers to the practice of going through all the tools, materials, etc. In the
work area and to keep only essential articles. Everything else is either stored
offsite or discarded. This leads to less dangerous and less clutter.
The goal is to eliminate non-essential elements of the workplace. The articles
are red tagged " and stored in a local red label area during a specific period of
time, typically five days. If not recovered by the working group, the items are
then moved to one of the central areas of the business of red tags. Here
everyone can sift through the elements to see if there is anything they need.
When the items were in the central area for a specific period of time, the
company has them through resale, donation, recycling or trash.

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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

S2- Shine
Step S2 - service includes three main activities include getting the work area
clean, maintaining its appearance, and the use of preventive measures to keep
it clean.
Shine the workplace by removing dirt, dust , liquids, and other debris . Each
team member must be equipped adequate cleaning supplies that have been
tested to ensure that the solution will not harm any equipment or work areas.
Teams can clean things such as equipment, tools, work surfaces, offices,
storage areas, floors, lighting, and anything that affects the overall cleanliness;
A team can also paint or coating work surfaces, equipment, floors, and walls.
The service process should not be left to a special concierge crew. To ensure
that each participates and collaborates, each team should establish a regular
schedule for routine cleaning and deep cleaning.

S3- Set in Order


Team members come together and share the knowledge they have acquired in
S1 and S2. They analyze the work area for further improvement opportunities
and look for ways to reduce the sources of waste and the error and make the
most visually instructive work environment. The team brainstormed possible
solutions, with special emphasis on the use of visual resources to achieve
improvements. Be sure to get feedback and approval stakeholders (production,
maintenance, security, management, etc.) before making changes.

S4- Standardize
During the implementation phase, the team identifies the means to establish
best practices in the workplace as standard. The aim of standardization is to
create best practices and get each team member to use the established best
practices in the same way.
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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

In order to standardize, roles and responsibilities must be clearly and


consistently applied. This can be accomplished through visual controls such as
color-coding, flow charts, checklists, and labeling to help reinforce a
uniformed approach.

S5- Sustain
The purpose of S5 - Sustain is to maintain the momentum generated during the
initial event or project. Management verification process must be put into
practice to ensure that employees understand that maintaining the level of
Work organization is a top priority. Management audits should focus on
ensuring that the routines and schedules Standardize specified in S4 are
properly maintained. The audit also provides an excellent opportunity to ask
questions and suggestions that stimulate other improvements.

Applications of 5S
5S in the workplace
Many manufacturing facilities have chosen to follow a path of "5S"
methodology and organizational housekeeping in the workplace as part of
continuous improvement and lean manufacturing processes.
5S is a system to reduce waste and optimize productivity through maintaining
an orderly workplace and using visual cues to achieve more consistent
operational results (see chart below). The term refers to five stages - so , set in
order , shine , standardize and sustain - which are also sometimes known as
the five pillars of a visual work. 5S programs are usually implemented by
small teams working together to get materials closer to operations, right at the
fingertips of workers and organized and labeled to facilitate operations with
the smallest amount of time and lost material .
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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

The 5S system is a good starting point for any improvement efforts to drive
out the waste from the manufacturing process, and ultimately improve the
profitability of a business by improving products and services, and reducing
costs. Many companies seek to make operations more efficient, and the
concept is particularly attractive for older manufacturing facilities seeking to
improve the bottom line by reducing costs.

The 5 pillars of a visual workplace


Implementation of the 5S method means cleaning and organization of work in
its current configuration. This is usually the first lean method that
organizations implement. This lean method encourages workers to improve
their working conditions and helps them learn how to reduce waste, unplanned
downtime, and ongoing inventory.
A typical 5S implementation would result in significant reductions in the size
of the space to existing operations. It would also result in the organization of
tools and materials in a color-coded labeled and storage locations, as well as
"kits" that contain just enough to complete a task.
The 5S methodology is a simple and universal approach that works in
businesses all over the world. It is essentially a support for these other
manufacturing improvements just-in- time (JIT) production, cellular
manufacturing, total quality management (TQM), or Six Sigma initiatives, and
is also a great contributor to making the workplace a better place to spend time
.
Table 1 (below) outlines the five pillars, with a brief definition of what it
means to step in a manufacturing context, why it is important, and the list of
issues, he avoids if implemented.

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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

Pillar

Sort

What does it
mean?

Why is it
important?

What problems are


avoided?

Remove all
items not needed
for current
production
operations.
Leave only
the bare essentials:
When in doubt,
throw it out.

Space, time,
money, energy, and
other resources can
be managed and
used most
effectively.
Reduces
problems and
annoyances in the
work flow.
Improves
communication
between workers.
Increases
product quality.
Enhances
productivity.

The factory
becomes increasingly
crowded and hard to
work in.
Storage of
unneeded items gets
in the way of
communication.
Time wasted
searching for
parts/tools.
Unneeded
inventory and
machinery are costly
to maintain.
Excess stock
hides production
problems.
Unneeded
items and equipment
make it harder to
improve the process
flow
Motion waste.
Searching
waste.
Waste of
human energy.
Waste of
excess inventory.
Waste of
defective products.
Waste of
unsafe conditions.

Arrange
Set in order needed items so
Eliminates many
that they are easy to kinds of waste,
use.
including:
Label items
so that anyone can
Searching
find them or put
waste.
them away.
Waste due

Shine

Keep
everything, every
day, swept and
clean.

to difficulty in
using items.
Waste due
to difficulty in
returning items.
Turn the
Lack of
workplace into a
sunlight can lead to
clean, bright place poor morale and
where everyone
inefficient work.
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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

will enjoy working.


Defects are
Keep things less obvious.
in a condition so it
Puddles of oil
is ready to be used and water cause
when needed.
slipping and injuries.
Machines that
do not receive
sufficient
maintenance tend to
break down and cause
defects.
Integrates
By ensuring
Conditions go
Standardize Sort, Set in Order, conditions do not back to their old
and Shine into a
deteriorate to
undesirable levels.
unified whole.
former state,
Work areas
facilitates
are dirty and
implementation of cluttered.
the first three
Tool storage
pillars.
sites become
disorganized and time
wasted searching for
tools.
Clutter starts
to accumulate over
time.
Backsliding
occurs.
Making a
Consequenc
Unneeded
Sustain
habit of properly
es of not keeping to items begin piling up.
maintaining correct the course of action
Tools and jigs
procedures.
greater than
do not get returned to
consequences of
Instill
their designated
keeping
to
it.
discipline necessary
places.
to avoid
No matter
backsliding.
how dirty equipment
becomes, nothing is
done to clean it.
Items are left
in a hazardous
orientation.
Dark, dirty,
disorganized
workplace results in
lower morale.
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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

Benefits to society of using the 5S method include improved quality, lower


costs, promote safety, customer confidence building, more to the factory to
time and lowering repair costs.
The 5S methodology is usually implemented using a 3-step process, which
includes the establishment of a cross-functional team (including employees
working in related fields), visit all the areas related to manufacturing processes
to study and reflection on ways to improve the organization to reduce waste.
For example, plants have more than their share of seeking waste.
It is not unusual for a three-hour shift routine that includes 30 minutes of
research. When attempting to reduce the transit time dramatically (eg, from 3
hours 10 minutes), it is clearly no place for 30 minutes of research waste.
Value Stream Mapping (VSM) can be used in the 5S process to analyze the
materials, processes and information flows. The information is used to develop
a map of the state, which sets out how things were done in the past. The team
then analyzes the current state map to identify opportunities for organization
and housework improvement maintenance. A wide range of ideas is
considered - so that all ideas will not end up being viable, all are worthy of
investigation. The key is to observe the non- value added processes and to
create an environment to promote the value added through labor waste
disposal.
Finally, the team is planning a future state based on exercise and begins the
implementation of the future state. The process is iterative; the future state
becomes the current state, and a continuous improvement process should be
used to identify new ways to reduce waste. Waste is defined very broadly, and
includes things like waste in the motion of matter, carrying too much
inventory, defects or rework, producing scrap, waiting or unnecessary
movement.

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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

Some examples include waste movement because the person sent for part or
tool could not find it; Search waste because nobody can find the key to the
locked cabinet which contains the necessary tools; waste from defective
products because defective parts were not properly separated and used in
error; and even the waste caused by hazardous conditions, such as boxes of
supplies that are left in a passage, causing someone to stumble and get hurt.
For example, team members can observe long distances off workers to obtain
the necessary documents, or spend time reaching into bins on the shelves to
find parts. Or they can identify the hardware, such as nuts, bolts and screws
that are used in a certain area, but stored in a central storage center near the
point of use. The goal of VSM is for the team to walk the process, and identify
what operators really need and what they get.

The role of storage in the 5S workplace organization


methodology
As mentioned , one of the pillars 5S is to identify and eliminate many types of
waste, including time lost searching articles, waste due to difficulties in the
use of elements and losses the difficulty of returning items . Storage solutions
are important in implementing waste disposal by reducing space, improving
the organization and management of stocks. Storage cabinets and workbench
products that allow dense storage, a small footprint and visual organization
near where the tool is needed, become a key factor in the implementation of
the 5S program.
Systems should be set up so everything has a place that is available when
needed, including the fabrication shop, areas where the products are packed,
through the maintenance area of the equipment. Everything must be labeled
and identified. Local storage minimizes travel time and storage and adjustable
set make it easier to adapt to the different needs of individual employees.

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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

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MN 4001
Assignment No1

2013106 AD1
Indravarman Rajeswaran

Conclusion
5S is an approach that can be easily applied in all organizations. Its simplicity
and easy recognition is the upper side of 5S. 5S is not a study over a period of
time; it is rather a method to defend the requirement of standardization and the
pursuit of all the improvements were made.
A successful application depends 5S training to be provided by the directors to
the staff. Even a small light that can form during training challenges the
achievement of expected results. These types of studies should be
continuously supported by training programs planned.
For better execution of 5S activities under the company and the performance
of controls in a regular manner, the quality management departments
engineers have been commissioned. 5S activities applied in the assembly
department of the surveyed company have been reviewed for 28 weeks and the
forms have been filled as a result of the weekly routine controls. Scores of
each week are summed up, so weekly total assessment scores are obtained and
the assessments are made through reflecting the weekly scores on the graphics.
Finally, the competition may be formed between the teams, departments,
companies, etc. groups in order to increase the efficiency of 5S system at the
companies and granting award (salary, bonus, promotion, etc.) to the team
became successful at the end of the process by the directors may facilitate the
supply of high success in 5S application in a short time.

Reference
1) 5S/ Visual Workplace Handbook_PAC( www.gotopac.com)
2) Erdal M (2007). 5S system cleaning and order management.
www.meslekiyeterlilik.com
3) Anon (2007). 5S Management,

http://vdb.gib.gov.tr/edirnevdb/sunumlar/5sSunum/5sy.html

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