5 S - A Presentation

8/9/2019 5 S - A Presentation

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What is 5S ?

55SS is a method to reduce waste, increase the safety and

optimise productivity through maintaining an orderly

workplace to achieve more consistent operational results.

Five S drives a cleaner environment and organises the

workplace.

By implementing Five S we can rapidly have an impact on

our work environment and facilities with a minimal

expenditure. Most companies have reported 5% efficiency

improvement in several month's, which is sustainable over

time


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What is 5S ?

5S - five Japanese words starts with S

Japanese Term English Equivalent Meaning in Japanese Context

Seiri Tidiness Throw away all rubbish and unrelated materials in

the workplace

Seiton Orderliness Set everything in proper place for quick retrieval

and storage

Seiso Cleanliness Clean the workplace; everyone should be a

janitor

Seiketsu Standardization Standardize the way of maintaining cleanliness

Shitsuke Discipline Practice 'Five S' daily - make it a way of life; this

also means 'commitment'


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Seiri -- Sort

Seiton -- Set in order

Seiso -- Shine

Seiketsu -- Standardize

Shitsuke -- Sustain

What is 5S ?

An equivalent set of five 'S' words in English have likewise been

adopted by many, to preserve the "5S" acronym in English usage.


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5S simplifies your work environment

Reduces waste and non-value activity

Improved quality , efficiency and safety.

Every one notices the positive results insiders as well as outsiders.

Self disciplined

Create ownership in equipment and facility.

All these factors improves the image of company and it improves the

business.

Why to Implement 5S ?


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Why to Implement 5S ?

To survive, our company must stay

competitive.

Helps improving product quality,

Services and lowering the cost.

5-S system is a good starting point

for all improvement programs.


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Benefits of 5SPersonal:

Amore pleasant work place

More satisfying jobs

Removes obstacles and

frustrations in work

Increased personal

productivity

Makes it easier tocommunicate with everyone

you work with.


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Organizational:

Higher Quality

Lower Costs

Greater Customer

Satisfaction

Healthy work environment

Zero Waste

Benefits of 5S


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If you dont use it,

move it!

If you dont use it,

move it!

SEIRI (Sorting)S1


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1 - S (Seiri) SORTING Get rid of unwanted material

Look around your work area and ask yourself Is it really

necessary for all items to be there?

Things

Can be

used

Can NOT

be used

S1


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Inventoryitems

CANT BE USED

CAN BE

USED

Use frequency Description Sort Out Method

RARELYUSED

OCCASIONALY

USED

OFTEN

USED

DEFECTIVE GOODS

& DEAD INVENTORY

THAT WILL NOT BEUSED

USED ABOUT

TWICE A YEAR

USED WITH IN

ONE OR TWO

MONTHS

USED ABOUT

ONCE A WEEK

USEDEVERY

HOUR, EVERY

DAY

DISCARD

REMOVE OR STORE

ELSE WHERE

STORE NEAR

PROCESS WHERE IT

IS USED

STORE NEAR

OPERATION WHEREIT IS USED

KEEP CLOSE AT

HAND AT ALL TIMES

S1


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A place for everything

&

everything in its place

A place for everything

&

everything in its place

SEITON - (Set in Order)

Set In Order (Seiton) is theSecond of the 5Ss and

focuses on efficient and

effective storage methods

S2


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Arrange items according to priority.

The items not required frequently- Keep at a

distance. The items required frequently- Keep at nearest

possible location.

Heavy and large item Keep at floor

Identify all items, Places, areas, by labels,

Identification boards.

A place for every thing and everything in its place

SEITON - (Set in Order)S2


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Seiso means cleaning the work place and all the equipments

by ourselves.

SEISO (Shine i.e.,Shine Cleaning)S3


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SEISO (Shine i.e.,Shine Cleaning)

Once you have eliminated the clutter and junk that has been

clogging your work areas and identified and located the necessary

items, the next step is to thoroughly clean the work area. Daily

follow-up cleaning is necessary in order to sustain this improvement.

Take pride in a clean and clutter-free work area and this step will

help create ownership in the equipment and facility.

S3


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Shine means Inspection

When you clean an area,

you also do some

inspection of machinery,

equipment, and working

conditions.

S3


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SEIKETSU (Standardization)

MAINTENANCE OF SEIRI , SEITON & SEISO

Fourth S Emphasizes that SEIRI, SEITON and

SEISO should become a part of life.

S4

Even a clean work place, properly selected and with proper

arrangement, will soon become dirty if Seiri, Seiton and Seiso are

not continuously repeated. Let us keep our area neat and clean,

through which we will achieve SereneAtmosphere.


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Once the first three of the 5Ss have been

implemented, you should concentrate on

standardizing best practice in your work area. Allow

your employees to participate in the development

and documentation of such standards.

SEIKETSU (Standardization)S4


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This is by far the most difficult S to implement andachieve. Human nature is to resist change and

more than a few organizations have found

themselves with a dirty cluttered shop a fewmonths following their attempt to implement 5S.The tendency is to return to the status quo and

the comfort zone of the "old way" of doing things.Sustain focuses on defining a new status quo and

standard of work place organization.

S5 SHITSUKE (Sustain)


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SHITSUKE (Sustain)

Make a habit of

using correct

procedures. Without sustain,

the first four pillars

cant bemaintained.

S5


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SHITSUKE (Sustain)

Strictly follow the rules and standards while working.

Strictly follow punctuality e.g. reaching office in time, reach for meeting in time.

Following of operation standards by operators every time.

Always follow safety standards to avoid accidents.

Attendance Shortage of man power leads to -

1. Line stoppage.2. Bad product quality

3. Overburdening of other operators

4. Can cause accidents due to high work pressure.

S5


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Not only will employees feel betterabout where they work, the effecton continuous improvement canlead to less waste, better qualityand faster lead times. Any of whichwill make your organization moreprofitable and competitive in themarket place.

RESULTS

Once fully implemented, the 5S process can increase morale, create

positive impressions on customers, and increase efficiency and

organization.


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Systematic Systematic

Organization- Identifying what

items are required and which

are not.

Sorting Visual Placement-

Items should be easilyretrievable, easy to get, and

visual-easy to see.

Self-Discipline/Control-

Ensuring that Systematic

Organization, Visual

Placement & Cleanliness

are maintained.

Scrubbing Clean-Keep the area free from debris,

dirt, oil, items not needed.

Standardizing Control-

Maintain and continually

improve the previous

improvements.

The Five Elements of 5S


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SHITSUKE

(SUSTAIN)MAKE A HABIT OF

MAINTAININGESTABLISHED

PROCEDURES

SEIRI

(SORT)

SEITON

(SET INORDER)

SEISO

(SHINE

CLEANING)

SEIKETSU

STANDARDIZATION

5 S


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Systematic

Organization

CleanlinessVisual Placement

Standardization

5 S

Implementation

Plan

Progressive

Enhancements

Step 1

Establish 5 S

Implementation Team

Step 2

Develop Specific

Implementation Plan

Step 3

Develop Communication

Plan

Step 4

Develop 5 S Training Plan

Step 5

Implement 5 S

Step 6

Verification of Effectiveness

5S Implementation plan


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ManagementCommitment

Awareness training

to Managerial Staff

Supervisor's/Workers

Training

5S audit committee

5S audit schedule



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Identification

of Audit areas

Display of audit

check list

Regular 5S Audits

Display of 5S data



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Management responsibilities ?

Define the Scope

Provide the resources I.e trainings, transportation,

facilities etc.

Formation of a audit committee.

Incorporation of 5S audit marks in performance

appraisal of all concerned.

Plant level 5S score should be one of the managingpoint of unit head.


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Removing Red Tagged stuff

What Stuff would you Red Tag in these pictures ?

Picture A__________________________________________________________

Picture B _________________________________________________________

ThinkBreak


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In the following pictures, identify some of the finding wastes ( assume you work in a

distribution center and you have to fill an order with product located in the following

pictures).

___________________ ___________________ _________________

___________________ ___________________ _________________

___________________ ___________________ _________________

___________________ ___________________ _________________

Everything has a useable place

ThinkBreak

Finding Wastes


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Some evidence of standardized work areas

Clear, shiny aisle ways

Color coded areas

Slogans, banners

No work-in-process ( WIP )

One-Piece Flow

Standardized Work Sheets


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DAILY 10 MINUTES 5 S PRACTICE IN

MANUFACTURING

Check your own clothing

Check for any leakage or drops and pick up any parts,

work trash or whatever that is on the floor

Wipe the temperature, position markings and other

important places with a rag

Wipe up any water, oil or whatever may have spilled or

leaked

Realign anything that is out of place


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Clean up the plates and label and make sure that

they are clearly legible

Wipe the main places on the machinery with a rag

Make sure all of the bits and tools are where they

should be.

Get rid of anything that is not needed there


MANUFACTURING


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Wipe the key parts and on the places on the

machinery with a rag

Fix any labels that may be coming off

Clean the floor

Get rid of the trash in trash bins

Check the labels, instructions and oil inlets and fixanything that is amiss


MANUFACTURING


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January 2007 June 2007


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Its the

ATTITUDE that

makes the

difference


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THANK YOU

THIS IS NOT THE END BUT TO

START WITH

LET US PRACTICE TOGETHER

5 S - A Presentation

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