Training Session

5S

on

Part 1 - What is 5 S
&

Part 2 - How to Implement 5 S

Now, we will see ! Part 1 - What is 5 S

Impact of 5 S at the Workplace

QUALITY SAFETY EFFICIENCY CONTROL

Equipment
Material Jigs/Tools Method Workers Products Timeliness
Motivates

Customer Satisfaction

Employee Satisfaction

INDIA

1950

1960

1970

1980

What are the 5 S?

Seiri Seiton - Sorting - Systematic Arrangement

Seiso

- Cleaning

Seiketsu - Standardization

Shitsuke - Training & Discipline

We Will See First .!

What is

SEIRI
(SORTING)

Seiri - Sorting

SEIRI - SORTING /REORGANISATION To clearly devide objects in to two groups Those items that are necessary.

And Those items that are not necessary.

To get rid of the unnecessary and to keep the necessary.

Seiri - Sorting

WHAT IS UNNECESSARY
Item is not needed.
Item is needed however, quantity in stock is more than what is needed for consumption in near future Contingency Parts : Critically decide the quantity of contingency parts to be retained and criteria for such parts.

Organisation Frequency of use LOWThings you have not used in the last one year. Things you have used once in the last 6-12 months. Things you have used only once in the last 2-6 months. Things used more than once a month. Things used once a week Things used daily or hourly

Seiri - Sorting

Storage Method Throw them out

HIGH

Store at distance OR Keep in store Store it in central place in your zone. Store it in the central place in your zone Store near the workplace. Store near the workplace.

Seiri - Sorting

Organisation

Identifying unnecessary
1) Parts and Work in Process (WIP)
Things fallen back behind the machine or rolled under it. Broken item inside the machine Things under the rack/platforms. Extra WIP Stock of rejected items Items accumulated over period for rework Material awaiting disposal decision Material brought for some trail, still lying even after trail Small qty of material no longer in use

Cont..

Seiri - Sorting

Organisation

Identifying unnecessary
2) Tools, Toolings, Measuring devices
Old jigs, tools not in use lying. Modified tools, tooling for trial, are lying after trail. Worn out items like bushes, liners, toggles etc. lying. Broken tolls, bits etc. may be lying. Measuring equipment not required for the operation being performed, is lying.

3) Contingency parts
Many times storage place for contingency parts become a last refuge for broken parts, surplus items and things nobody is likely to use. Cont..

Seiri - Sorting

Organisation

Identifying unnecessary
4) Shelves and Lockers
Shelves and lockers tends to collect things that nobody ever uses, like surplus, broken items etc.

5) Passage and Corners :

Dust material not required seem to gather in corner.

6) Besides Pillars and under the stairs:

These place tends to collect junk, spittoon etc.

7) Walls and Bulletin Boards

Old out dated notices which have lost their relevance Posters or bulletins on wall Dust, remain on torn notices, cell tape pieces Cont..

Seiri - Sorting

Organisation

Identifying unnecessary
8) Floor, Pits, Partitions
Defective parts Protection caps, covers Packing material Hardware items, small items Even tools,small items Even tools, tooloing Items dropped on the floor are never picked

9) Computer Hard Disk

Many unwanted, outdated, temporary files pile up
Cont..

Seiri - Sorting

Dealing with papers

How to reduce papers on your table?

1) Make a single pile of papers
2) Go through them and sort in following categories : a) Immediate action b) Low priority c) Pending d) Reading material e)For information

Seiri - Sorting

Dealing with papers

How to reduce papers on your table?

4D principle DO... DELEGATE. DELAY. DUMP.

Now,We Will the Second one ...!

What is

SEITON
(SYSTEMATIC ARRANGEMENT)

Seiton - Systematic Arrangement

SEITON
A Place for Everything And... Everything in its Place !

Seiton - Systematic Arrangement

How to achieve Systematic Arrangement?

Decide where things belong Decide how things should be put away Obey the Put away rules

Seiton - Systematic Arrangement

How to achieve Systematic Arrangement?

Decide where things belong - Standardize Nomenclature - Determine an analytical method for storage Decide how things should be put away - Name & location to everything. Label both item and location - Store material functionally - Prevent mistake with coding by shapes & colour
contd.

Seiton - Systematic Arrangement

How to achieve Systematic Arrangement?

Decide how things should be put away - Follow first in first out rule - If two identical items are to be located, then store them separately, colour code them.

Obey the rules - Put the things back to their location after their use

Seiton - Systematic Arrangement

How to achieve Systematic Arrangement?

USE:

1) Signboard
2) Colour codes 3) Outline marking 4) Labels

Seiton - Systematic Arrangement

Functional Storage

Seiton - Systematic Arrangement

Functional Storage
Usage Frequency Weight & Shape of the Material * Store frequently used material near the workplace and less frequently at some distance * Heavy material should be stored at lower levels/layers Place directly on the material handling device for case of handling

Seiton - Systematic Arrangement

Functional Storage
Category * Same category of material may be stored in one location. Eg. Allen Screws, Oil Seals * All items required for an operation may be stored in one location. Eg. Allen key, spanner etc. hand tools required for setting m/c

Operation Wise

Seiton - Systematic Arrangement

Functional Storage
Outlining and Placement Marks -Marks boundaries of dept. aisles, Machines -Follows straight line, right angle rule -Nothing shall be kept outside the boundaries Stand and shelves -Keep only required number of stands and shelves -Standardize height, size -Provide casters where necessary so that it can be move

Seiton - Systematic Arrangement

Functional Storage
Wires and Ducts - Colour code - When there are multiple connections bundle the wires, label them and lake sure that they are in straight line / right angle and firmly anchored Machine -tools & Tools - Put the tools in the order you need them - Location of the tools should be such that it can be put away with one hand - Try to eliminate some hand tools by permanently attaching it to the bolt head

Seiton - Systematic Arrangement

Functional Storage
Blades, Dies other important consumables - Stores them in the protected place - Maintain these things regularly by applying rust preventive, oiling etc. WIP Work In Process - Designate a place for each component / part - Decide on how much quantity to be stored - Ensure that there is no damage to good part during transit, they do not get rusty and they are not mislabeled.

Seiton - Systematic Arrangement

Functional Storage
Oils - Reduce number of oils used (Standardize) - Colour code for oil - Safety aspects fire prevention, pollution, leak, spillage Instrumentation & Measuring Devices - Label them, show direction of flow

Now,We Will the Third ...!

That is

SEISO
( CLEANING )

Seiso - Cleaning

SEISO
Clean workplace completely so that, there is no dust on the floor, machines and equipments !

Seiso - Cleaning Activity - Keep workplace spotlessly clean - Inspection while cleaning - Finding minor problems with cleaning inspection Success - Reduction in machine down time Indicator - Reduction in no. of accidents

Seiso - Cleaning

While cleaning up and getting rid of dirt and unclear items potential defects such as Abrasion, Damage, Loose Parts, Deformities, Leaks, Vibration, Abnormal Sound etc., are revealed and hence Seiso is inspection

Seiso - Cleaning Here

cleaning means more than just keeping things clean. Cleaning should be viewed as a form of Visual Inspection

Preventive measures should be taken to tackle problems of dust, grim, burrs, leakage etc. Roots cause of the problem should be identified and it should be eliminate

Seiso - Cleaning

5 Minutes Every day for cleaning Devote 5 minutes every day for cleaning your work area Participation of everyone is required Attack hard to clean places regularly

Seiso - Cleaning

Cleaning - Inspection Points for most equipment

Tightening Loose bolts, welding detachment, loose parts, vibration or bumping noise, friction Heat Oil tanks, motors, heaters, axles, control panels, washing/cleaning water, bearing, wiring etc.

Seiso - Cleaning

Cleaning - Inspection Points for most equipment

Breakage, Cracks Breakage, cracks dent on sliding parts, handle has come off, broken switches, wire joints come off, wires are broken or crack dial of various pre, gauge, meters etc.

Now, Fourth S is ...!

SEIKETSU
( STANDARDISATION )

Seiketsu - Sandardisation

SEIKETSU
Setting up Standards / Norms for a neat & clean workplace and details of how to maintain the Norms(Procedure) ...

Seiketsu - Sandardisation

Maintain & Improve The Standard of : Seiri Seiton Seiso

Seiketsu - Sandardisation

Regularizing 5S activities so that abnormalities are revealed. Make it easy for everyone to identify the state of normal or abnormal condition For maintaining previous 3 S, deploy visual management

Seiketsu - Sandardisation

Visual Management

It has been estimated by scientific study that 60% of all human activities starts with sight 5S is easy to do once. It is consistency that is difficult. That is why Visual Management is so important, so that evreybody will know that there is some problem.

Seiketsu - Sandardisation

Visual Management

What visual controls communicates? It grabs one or more of our senses in order to Alert us to an abnormality Help us recover quickly Promote adherence and prevention Enable successful self management

Seiketsu - Sandardisation

Visual Management

Some method for visual communication : Colour coding Use of Labels Danger Alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators

Seiketsu - Sandardisation

Visual Management

Some method for visual communication :

Labels:
Precision management labels Inspection Labels Temperature Labels Responsibility labels

Seiketsu - Sandardisation

Visual Management

Points to remember in making visual control tools : 1) Make them easy to see from distance 2) Put the display on the things 3) Everyone can tell what is right and what is wrong 4) Anybody can follow them and make necessary corrections easily 5) Work place should look brighter & orderly

Seiketsu - Sandardisation

Visual Management

Some everyday visual management example : Traffic signal Zebra crossing In car - Petrol indicator - Speed Indicator Direction arrows Electric danger sign etc.

Seiketsu - Sandardisation

Visual Management

Some visual communication signs :

And, Fifth S is ...!

SHITSUKE
(TRAINING & DISCIPLINE)

Shitsuke - Training and Discipline

We need everyone to maintain 5S guidelines. To maintain DISCIPLINE, we need to practice and repeat until it becomes a way of life. Discipline is the Core of 5S

Shitsuke - Training and Discipline

Discipline means making a steady habit of properly maintaining correct procedures. Time and effort involved in establishing proper arrangement and orderliness will be in vain if we do not have discipline to maintain it.

Shitsuke - Training and Discipline

Pledge It shall be my constant effort to maintain my workplace in good order by Assign a place for everything & keeping everything in its place Sorting out unwanted material periodically and discarding them Keeping my work area neat & clean everyday

Part 2 How To Implement 5S

How To Implement 5S

Step 1 Form a 5S Committee OR 5S Coordicator

How To Implement 5S

Step 2 Divide the Workplace into various Zones

How To Implement 5S
5S format 1 Zone at work Group Area Type of Audit Line/ Section Zone No.

How To Implement 5S

Step 3 Allocate Zones to the relevant people

How To Implement 5S

Step 4 Start Implementing Seiri Seiton Seiso

How To Implement 5S

Step 5 Audit the 5S Implementation Process

How To Implement 5S
5S format 2 5S Audit Calendar For the month of : S. No. Name Area of Audit Type of Audit Zone Dates

How To Implement 5S
5S format 3 5S AUDIT CHECKLIST SUPPORT GROUP Mark Range 1-10 Marks 5S Points 1. SEIRI (SORTING) a) ITEMS/PROCESS MATL/INSTRUMENTS SORTED & IDENTIFIED AS OK, Usable immediately Usable (Spares) Good, Not Required Rework Scrap b) FILES AND RECORDS SORTED AND IDENTIFIED AS Current/Follow up Not Required (to be sent to Record Room) c) ANY ITEM /FILES/RECORDS LYING UNSORTED SUB-TOTAL 2. SEITON (SYSTEMATIC ARRANGEMENT) a) Table, Chairs, Cupboards, Racks & Bins Neatly Arranged b) Items neatly arranged and identified as Under process/Spares/Scrap c) Arrangement of files in Filing Rack d) Any items /files lying haphazard SUB-TOTAL 3. SEISO (Cleanliness) a) Tables, Chairs, Machines b) Surroundings Area free of oil, chips, cotton waste etc. c) Floor, wall, (Including Glass of Windows & Ventilation) Ceiling (Tube Light, Fans & Roof) d) Measures taken to consume electricity SUB TOTAL TOTAL Signature of Zone Member Sign of Auditor Date Name Dept 1-5 1-5 1-5 1-5 1-5 1-5 1-5 0 or 5

1-5

1-5

How To Implement 5S
5S format 4 5S AUDIT CHECKLIST PRODUCTION GROUP Mark Range 1-10 Marks 5S Points 1. SEIRI (SORTING) a) ITEMS/PROCESS MATL/INSTRUMENTS SORTED & IDENTIFIED AS OK, Usable immediately Usable (Spares) Good, Not Required Rework Scrap b) FILES AND RECORDS SORTED AND IDENTIFIED AS Current/Follow up Not Required (to be sent to Record Room) c) ANY ITEM /FILES/RECORDS LYING UNSORTED SUB-TOTAL 2. SEITON (SYSTEMATIC ARRANGEMENT) a) Table, Chairs, Cupboards, Racks & Bins Neatly Arranged b) Items neatly arranged and identified as Under process/Spares/Scrap c) Arrangement of files in Filing Rack d) Any items /files lying haphazard SUB-TOTAL 3. SEISO (Cleanliness) a) Tables, Chairs, Machines b) Surroundings Area free of oil, chips, cotton waste etc. c) Floor, wall, (Including Glass of Windows & Ventilation) Ceiling (Tube Light, Fans & Roof) d) Measures taken to consume electricity SUB TOTAL TOTAL Signature of Zone Member Sign of Auditor Date Name Dept 1-5 1-5 1-5 1-5 1-5 1-5 1-5 0 or 5

1-5

1-5

How To Implement 5S
5S format 5 5S AUDIT CHECKLIST ADMINISTRATIVE GROUP Mark Range 1-10 1-5 0 or 5 SUB-TOTAL 2. SEITON (Systematic Arrangement) a) Work Table, Chairs and Personal Belongings b) Layout of office & office equipment (filling cabinet, Waste Paper Bins, Computers & Stationary c) Any items/ Files Lying Haphazard SUB TOTAL 3. SEISO (Cleanliness) a) Tables, Chairs, Computers b) Cupboard, Filing Cabinet c) Floor, wall, (Including Glass panes of Windows & Ventilators) Ceiling (Tube Light, Fans & Roof) d) Measures taken to consume electricity SUB TOTAL TOTAL Signature of Zone Member Sign of Auditor Date Name Dept Marks 5S Points 1. SEIRI (SORTING) a) Records, files with clear Labeling b) Memos / Letters Sorted out for Filling/ Action/ Follow-up c) Any Items/Files/Records lying unsorted

1-5 1-10 0 or 5

1-5 1-5 1-5 1-5

How To Implement 5S
5 S NOTICE BOARD
1 AREA PROBLEMS FOR GROUP 5S ASSESMENT CHART DATE

ZONE

LEADER

TODAY

TODAY AVERAGE

LAST MONYH AVERAGE

SEIRI 4 PARTICIPANT SEITON SEISO TOTAL

How To Implement 5S

Step 6

Give Recognition to best 5 S Team

Thank You