Work Environment - (5S)

1S - SEIRI 2S - SEITON 3S - SEISO

- SEGREGATION - SYSTEMATIC ARRANGEMENT - SPICK & SPAN

4S - SEIKETSU - STANDARDISING 5S - SHITSUKE - SELF DISCIPLINE A SOURCE OF PRIDE

Work Environment - (5S)

Products / Services

Customer Satisfaction

Work Environment - (5S)

SSS S E I S O

SEITON SEIRI

S E I K E T S U

S H I T S U K E

Work Environment - (5S)

5S stands for five good housekeeping principles. 5S becomes a base for continuous improvement. 5S principles are very effective systematic approach for improving our work environment and total quality. 5S are participation programme. 5S is based on the belief that every individual can contribute to improve his/her workplace where he / she spends one third of his / her life.

What are 5S ?

Objectives of - 5S
Creating a neat and clean workplace. Systematize day to day working. Improve work efficiency. Standardize work practices. Improve work discipline. Improve productivity. Improve quality.

What do we get from practicing 5S activities ?????

Employee
1. All working area in proper order. 2. Create more vital working atmosphere. 3. Cheerful / good mood. 4. Safe environment. 5. Higher work efficiency. 6. Create work effectiveness. 7. Take Pride.

Organisation
1. Increase production efficiency. 2. Reduce unnecessary work. 3. Low production cost. 4. More space and storage are obtained. 5. World class company is expected. 6. Obvious factory. 7. Confidence and recognition are obtained.

5S5s

1S - SEIRI - SEGREGATION
SEIRI means to distinguish between what is necessary and what is unnecessary in accordance with specific rules and principles and get rid of what you do not need. Saving things and information which one does not need consume extra space and create more wok. SEIRI is excellent way to gain valuable floor space and eliminate scrap and excess raw material.

1S - SEIRI - SEGREGATION
What is the criteria to distinguish necessary and unnecessary ?

Unnecessary things with no value Unnecessary things with value Things still used and needed

/ / /

Throw away / get rid of Put for sale Place in the right location and identify with tag Lost and Waste Lose Brand loyalty

Acceptable product mixed with / reject Reject mixed with acceptable one /

Customer does not pay for waste.

1S - SEIRI - SEGREGATION
How to implement SEIRI - 1S ?
 Clarify standards to judge the necessary things from the unnecessary.  Segregate the things in compliance with the set standard. Extended decision making is prohibited.  Schedule the itinerary checking by promotion committee members.  Eliminate the space to store unnecessary things in order to expel such things. Do not hurry to expand the space. The goods which cannot be sold are unnecessary.

1S - SEIRI - SEGREGATION
Where unnecessary things can be found ?
Shelves & Lockers - surplus/broken articles Passageway and corners- useless articles Behind pillars and under stairs- materials, defective Warehouses and sheds- materials/in process articles Walls and bulletin boards- expired notice Behind and also under the machines-broken articles Under the floor and side ditches- scrap Materials and in process articles Outskirts ( Near the wall, fences, and drainage)

1S - SEIRI - SEGREGATION
Benefits from SEIRI Eliminate the excess use of space. Eliminate the excess equipment. Eliminates the excess use of file cabinet / shelf. Eliminates accidents. Eliminates errors. Eliminate waste of time Reduce cost of production.

2S - SEITON - SYSTEMATIC ARRANGEMENT

What to do with segregated necessary things ? SEITON means having things in the right place or right location. It is for the most efficient and effective retrieval. Make a system which enables anyone to take out the thing promptly.

A place for everything and everything on its place

2S - SEITON - SYSTEMATIC ARRANGEMENT

How to implement SEITON ? Fix the storage space. Clearly indicate the storage location. Unify the names of thing. Stratify things.
 Things which are used once or twice a year --to be stored in remote place.  Things which are used about once a month --to be placed collectively in the work place.  Things which are used daily --- to be placed within the work area.

2S - SEITON - SYSTEMATIC ARRANGEMENT

Decide how to put things. In relation to quality.
 Avoid placing the things which resemble each other together. Show the difference clearly.  Indicate the storage period.  Use the first in first out method (FIFO).  Distinguish clearly between good and inferior quality goods.

2S - SEITON - SYSTEMATIC ARRANGEMENT

Establish a storage standard.
 Being taken away--- Who did it, when is the return date?  Out of stock--- Is there backup supply?  Stock replenishment---Who places an order, to whom and for what quantity.

Way of eliminating the unproductive time spent in looking for necessary things.

2S - SEITON - SYSTEMATIC ARRANGEMENT

Decide how to put things. In relation to efficiency.
 Assigned place marking, putting things visibly in place.  Location --- self numbers  Layout --- minimization of movement.  Ease of removal and storing.

In relation to SAFETY
 Put heavy weights at lower place.  Prevent overturn and drops.

2S - SEITON - SYSTEMATIC ARRANGEMENT Benefit from SEITON

Helps to reduce time for finding useful material . Create work effectiveness. Create safe atmosphere. Easy to inspect and recognize when material are gone from their location.

3S - SEISO - SPICK AND SPAN

Are floors and machines cleaned for the sake of appearance???? SEISO means getting rid of waste, grime and foreign matter and making things clean. Make a system which eliminates the cause of dirtiness.

CLEANING AS A FORM OF INSPECTION.

3S - SEISO - SPICK AND SPAN

WHY to do SEISO ? SEISO ( Cleaning) is a philosophy and commitment to be responsible for all aspects of the things you use and to ensure that they are in tip top condition Dust, dirt, grime, foreign matter etc. are looked upon as the prime causes for unexpected failure of equipment, unhygienic environment and even accidents. Therefore SEISO should be viewed as way to eliminate these problems one by one. CLEANING IS A EVERYBODY BUSINESS.

3S - SEISO - SPICK AND SPAN

How proper cleaning to be done? Following steps to be followed for doing proper cleaning: Measures against the root of uncleanliness.
Investigation of the root of uncleanliness. Measures against the cause of uncleanliness Prevention of leakage prevention of scattering prevention of falling study of manufacturing method Correct looseness

3S - SEISO - SPICK AND SPAN

How to deal with places which cannot be cleaned easily ?  Devise effective means to collect and dispose of dust.  Review of dust collection capacity and method, cleaning equipment and method of washing.

Cleaning of workplace
Allotment of areas and equipment to be cleaned First allot the area by group, then allot a related job by person. Do Cleaning Detect abnormal condition while cleaning. Establish cleaning rules. Decide when to do cleaning.

3S - SEISO - SPICK AND SPAN

Cleaning of equipment Do cleaning by a check sheet. Wipe out dirt. Cleaning of clogged filters, pipes etc. Control of generation of heat and other temp. Correction of displacement. Teaching of equipment and facilities element General equipment and facilities check point Check point for cleaning. Check points for oil Check points for additional tightening check point for temperature control check point for breakage.

4S - SEIKETSU - STANDARDIZE
What do you mean by SEIKETSU Seiketsu means continually and repeatedly maintain 1S, 2S & 3S standard achieved. Make a system which enables quick detection of a disordered condition / state. It must be made possible for anyone to see the actual situation at a glance by means of the visual control

4S - SEIKETSU - STANDARDIZE
How to maintain 1S, 2S & 3S ? Standardization is a condition where the segregation, Systematic arrangement and Cleaning have been repeated and maintained. Introduce extensive visual controls so that abnormalities show up by themselves. Following steps to be followed to maintain and promulgate first three S more deeply. Points of visual control
Standards for what is good and bad are clear. Abnormal conditions are shown.

4S - SEIKETSU - STANDARDIZE
Tools of visual control Label - lubrication label, accuracy label, inspection label, label showing the person incharge, equipment number and category. Limit marking - meter zone, stop line, assigned place marking, danger alert. Visualization - Status indication, direction indication, maintenance display board, Instructions, colour code for pipes, picture of safety gadgets to be used in the area, direction sign for emergency points & fire extinguisher, Caution and operation reminders.

4S - SEIKETSU - STANDARDIZE

 PREVENTS THE 1S, 2S AND 3S RETURNING TO 0S !!!!!  PROPER AND NICE WORKING AREAS.  STANDARD OPERATIONS AND PROCEDURES.  CREATE EXCELLENT PHYSICAL AND MENTAL HEALTHS.

IT MEANS HAVING THE ABILITY TO DO THINGS THE WAY THEY ARE SUPPOSED TO BE DONE. THE EMPHASIS IS ON CREATING A WORKPLACE WITH GOOD HABITS AND DISCIPLINE.

Doing the right things as routine.

5S - SHITSUKE - SELF- DISCIPLINE SELFDiscipline means to get accustomed to the operation in compliance with standards. It is the discipline to honour faithfully the promises agreed upon by the fellow people. The purpose of SHITSUKE is to support the four S ( Segregation, Systematic arrangement, Spick & Span and Standardizing) as the means to satisfy such fundamental things. Keep practicing the activities through those procedure until they become habits.

5S - SHITSUKE - SELF- DISCIPLINE SELFDiscipline means thinking about the many problems that occur day to day and resolving to do better. People sometimes make the most unbelievable mistakes because they let their guard down- because they forget their discipline. Practice and more practice. When you assume that something is easy just because you have done it thousand of times, that is when you are most likely to get it wrong.

5S - SHITSUKE - SELF- DISCIPLINE SELFHow to instill discipline ? 1) Cultivation of habits Make clear what should be done. Do it every day with the participation and practice by every one. 2) Conduct training Train employees until they become capable of complying with standard. Make worker responsible for action and not for the results.

5S - SHITSUKE - SELF- DISCIPLINE SELFIt is very important to practice and more practice, because practice reinforces correct habits. It is very important to be strict about how things are done - even the little things.

Disciplined workplace is the most important thing to ensure Product Quality