5S - BASIC TRAINING What is 5S and why do we want to do it? ALOK SHARMA 22\06\2010.

$: 5S - BASIC TRAINING What is 5S and why do we want to do it? ALOK SHARMA 22\06\2010.$
5S - BASIC TRAINING

What is 5S and why do we want to do it?

ALOK SHARMA 22\06\2010

• Seiri – Sort (housekeeping)

• Seiton – Systematic Arrangement

(workplace organization)

• Seiso – Shine (Cleanup)

• Seiketsu – Standardize

• Shitsuke – Sustain (Self Discipline)

What is 5S ?

What is 5S ?

5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems).

These are foundational to Kaizen (continuous improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts.

5S is one of the activities that will help ensure any company’s survival.

5S

1. Sort - All unneeded tools, parts and supplies are removed from the area

2. Set in Order - A place for everything and everything is in its place

3. Shine - The area is cleaned as the work is performed 4. Standardize - Cleaning and identification methods are

consistently applied 5. Sustain - 5S is a habit and is continually improved Also - Work areas are safe and free of hazardous or

dangerous conditions

Some New Words

Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes

Some Japanese words one need to know: Kaizen-(pronounced “kai zen”) – Continual improvement

Muda-(pronounced “moo da”) - waste

Gemba-(pronounced “gim ba”) – workplace

Kanban-(pronounced “kon bon”) - Pull type inventory control system. Items are only produced to meet customer needs. The request to produce more is signaled from an upstream operation and/or customer orders.

KAIZEN: What it is?

1) Process Improvement

2) Observation

3) Use of New Paradigms

4) Short Time

5) Zero Investment

6) Human Development & Empowerment

7) Profits & Savings - Plenty

ALWAYS

CONTINUAL

CHANGE

GOOD

IMPROVEMENT

FOR THE BETTER

KAIZEN IS A JOURNEY FROM:

EVENT

RESULT

GROSS

ENFORMENT OF CHANGE

TO CAUSE

TO PROCESS

TO MICRO

TO INDUCEMENT OF CHANGE

KAIZEN IS CONTINUAL IMPROVEMENT

TIMETIMEIM

PRO

VE

ME

NT

IMPR

OV

EM

EN

T

KAIZEN: KNOW THE REALITY THROUGH YOUR SENSE

OBSERVATION INTELLIGENCE

PHYSICAL EFFORT

PARADIGM OF HIGH PRODUCTIVITY & QUALITY

KAIZEN AT GEMBA

GEMBA: PLACE OF WORK

GEMBA is where . . .

Value is added

Actual work is done to meet customer requirement

Problems are solved

Staff is responsible for providing support, not for giving instruction

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1. 5S Principles

Elimination of wasteElimination of waste Every body is involved, Every body is involved,

Co-operative effortCo-operative effort Attack root causeAttack root cause Human being is not Human being is not

infallibleinfallible

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2. Objectives

Improve housekeepingImprove housekeeping Make every individual Make every individual

responsible for responsible for housekeepinghousekeeping

Beautify by simple meansBeautify by simple means Productivity improvement Productivity improvement

by saving time, space etc.by saving time, space etc.

The ‘S’ Japanese Word What is involved Objective

1SSEIRI

(Sorting Out)

Segregate necessary from unnecessary

Remove what is not required

Decide on frequency of sorting

Saving and recovering Space

2SSEITON

(Systematic Arrangement)

Arranging in order

Place for everything, Everything in its place

Minimizing search time

3SSEISO

(spic and Span)

Cleaning the work place/ equipment

Attaining the warning bell

Inspecting for problems

Taking corrective actions faster

4SSEIKETSU

(Standardization)

Working Methodology

(Procedures & WI)

Achieving higher productivity and better quality

5SSHITSUKE

(Self Discipline)Forming the habit in form of Training and Discipline

Doing it right at First Time

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SEIRI = SEIRI = SortingSortingSEIRI = SEIRI = SortingSorting

Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary

items

Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary

items

Activity Establish a criteria for eliminating unwanted itemsEliminate unwanted items either by disposing

them or by relocating them.

Success Area saved or percentage of space available

Indicator

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SEIRI = SEIRI = SortingSortingSEIRI = SEIRI = SortingSorting

Japanese Meaning :

The Japanese meaning of “Seiri” is

to straighten and contain.

- Get rid of waste and put it in order according to rules

Japanese Meaning :

The Japanese meaning of “Seiri” is

to straighten and contain.

- Get rid of waste and put it in order according to rules

1 ‘S’ – Our respiratory system sorts oxygen and other gases. And exhales other gases which are unwanted for our body

1 ‘S’ - SEIRI

Sort for . . .

Not Needed at All

Needed but not Now

Needed but not here

Needed but not so much Quantity

1 ‘ S’

WANTED UNWANTED

1S – SEIRI : SORTING

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1. Item is not needed

2. Item is needed however quantity in stock is more than what is needed for consumption in near future

3. Contingency Parts

Critically decide the quantity of contingency parts to be retained and criteria for such parts

Seiri = SortingSeiri = Sorting What is unnecessary

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Frequency of use Storage Method

*Things you have not used in the past one year

Throw them out

*Things you have used once in the last 6-12 months

Store at distance OR Keep in store

LOW

*Things you have used only once in the last 2-6 months

Store it in central place in your zone

*Things used more than once a month

Store it in central place in your zoneAV

ERAG

E

HIGH *Things used once a week Store near the workplace

*Things used daily or hourly Store near the workplace

Organization

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Seiri = SortingSeiri = Sorting Identifying unnecessary

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

Contd..

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2. Tools, Tooling, Measuring devices• Old jigs, tools not in use are lying• Modified tools, tooling for trial, are lying after trial• Worn out items like bushes, liners, toggles etc. lying• Broken tools, bits, etc. may be lying• Measuring equipment not required for the operation being performed , is lying3. 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

Contd..

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4. Shelves and Lockers• Shelves and lockers tends to collect things that nobody ever uses , like surplus, broken items etc.5. Passages and Corners• Dust, material not required seem to gather in corner6. Besides Pillars and under the stairs• These places 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, remains of torn notices, cell tape pieces

Contd..

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8.Floor, Pits, Partitions• Defective parts• Protection caps, covers• Packing material• Hardware items , small items• Even tools, toolingItems dropped on the floor are never picked9.Computer Hard Disk• Many unwanted, outdated, temporary files pile up

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Seiri = SortingSeiri = Sorting Improvement methods

1. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system e.g. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for systeme.g. How to perform Seiri (sorting)

3. Check ListA check sheet is used to decide what sort of main systemand sub system are necessary.

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Seiri = SortingSeiri = Sorting Dealing with papers

How to Reduce Papers on Your Table ?

1. Make a single pile of papers2. Go through them and sort in following categories

a) Immediate actionb) Low priorityc) Pendingd) Reading materiale) For information

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Seiri = SortingSeiri = Sorting Dealing with papers

How to Reduce Papers on Your Table ?

4 D Principle4 D Principle

DO DELEGATE DELAY DUMP

2 ‘S’

Seiton : Systematic Arrangement

Arranging things in systematic way

2 ‘S’ – In our body there is a fixed place for every organ.

2 ‘ S’ - SEITON

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SEITION = SEITION = Systematic ArrangementSystematic ArrangementSEITION = SEITION = Systematic ArrangementSystematic Arrangement

Meaning To determine type of storage and layout that will ensure easy accessibility for everyone .

Meaning To determine type of storage and layout that will ensure easy accessibility for everyone .

Activity - Functional storage - Creating place for everything and putting everything in its place

Success - Time saved in searching

Indicator - Time saved in material handling

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SEITION = SEITION = Systematic ArrangementSystematic ArrangementSEITION = SEITION = Systematic ArrangementSystematic Arrangement

Japanese Meaning:

Dictionary meaning of Seiton is “to be correctly

prepared” and “to prepare correctly”.

In short these means : (a) arrange correctly in accordance with the correct method of

doing activities and

(b) make thorough preparations so that activities can be done even if they occur abruptly

Japanese Meaning:

Dictionary meaning of Seiton is “to be correctly

prepared” and “to prepare correctly”.

In short these means : (a) arrange correctly in accordance with the correct method of

doing activities and

(b) make thorough preparations so that activities can be done even if they occur abruptly

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Seiton = Systematic ArrangementSeiton = Systematic Arrangement

How to achieve Systematic Arrangement ?

• Decide where things belongDecide where things belong

• Decide how things should be put awayDecide how things should be put away

• Obey the Put away rulesObey the Put away rules

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How to achieve Systematic Arrangement ?• Decide where things belong - - Standardize Nomenclature - Determine an analytical method of storage• Decide how things should be put away - Name & locations to everything. - Label both item and location - Store material functionally - Prevent mistakes with coding by shapes & colour contd..contd..

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How to achieve Systematic Arrangement ?• Decide how things should be put away - - Follow (FIFO) 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

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USE :USE :

1 ) Signboards1 ) Signboards

2) Colour codes2) Colour codes

3) Outline markings3) Outline markings

4) Labels4) Labels

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UsageFrequency

• Store frequently used material near the workplace and less frequently at some distance

Weight &Shape of theMaterial

• Heavy material should be stored at lower levels/layers Place directly on the material handling device for ease of handling

Functional Storage

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Category• Same category of material may be stored in one location. e.g, Allen Screws, Oil Seals Operation

Wise

• All items required for an operation may be stored in one location. e.g, Allen key, spanner etc hand tools required for setting m/c

Functional Storage

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

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• Wires and Ducts - - Colour code - When there are multiple connections – bundle the wires, label them and make 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 tool 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

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• Blades, Dies, Other important consumables - - Store 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

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• 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

Before sort after sort

3 ‘S’Seiso : Cleaning

KIKEN KITSUI KITENOI

Clean the surroundings !

(DANGER) (PROBLEM) (DIRT)

3 ‘ S’ - SEISO

3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc

47

SEISO = SEISO = Cleaning Cleaning SEISO = SEISO = Cleaning Cleaning

Meaning Cleaning trash, filth, dust and other foreign

matter. Cleaning as a form of Inspection

Meaning Cleaning trash, filth, dust and other foreign

matter. Cleaning as a form of Inspection

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

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SEISO = SEISO = Cleaning Cleaning SEISO = SEISO = Cleaning Cleaning

Japanese Meaning :

Dictionary meaning “to clean up” and

“getting rid of dirt and unclean items”

While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection

Japanese Meaning :

Dictionary meaning “to clean up” and

“getting rid of dirt and unclean items”

While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection

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Seiso = CleaningSeiso = Cleaning

• Here cleaning means more than just keepingHere cleaning means more than just keeping things clean. Cleaning should be viewed as athings clean. Cleaning should be viewed as a form of Visual Inspectionform of Visual Inspection

• Preventive measures should be taken to tacklePreventive measures should be taken to tackle problems of dust, grim, burrs, leakage etc.problems of dust, grim, burrs, leakage etc. Root cause of the problem should be identifiedRoot cause of the problem should be identified and it should be eliminatedand it should be eliminated

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5 Minutes Every day for cleaning5 Minutes Every day for cleaning

• Devote 5 minutes everyday for cleaning yourDevote 5 minutes everyday for cleaning your work areawork area

• Participation of everyone is requiredParticipation of everyone is required

• Attack hard to clean places regularlyAttack hard to clean places regularly

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SL.No CHECKLIST TICK

1 Check Floors are clean

2 Check Work areas are clean

3 Check walls are clean

4 Check Pillars and Ceiling are clean

5 Check Windows are clean

6 Check Rooms and Electrical lights are clean

EXAMPLE : PREPARE CHECKLIST FOR CLEANING

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Seiso CycleSeiso Cycle

• BEFORE WORK, CLEAN AND INSPECT THE MACHINERY TOOLS, JIGS & FIXTURES.

• BEGINNING OF WORK - DO TRIALS AND START UP

• DURING OPERATION - CLEAN, INSPECT, DISCOVER AND DEAL WITH ABNORMALITIES

• AFTER COMPLETION OF WORK - DISPOSE OFF AND GET RID OF UN-NECESSARY THINGS

• SEISO IS A PART OF GOOD WORKMANSHIP• SEISO IS AN IMPORTANT PRE-CURSOR WITH 5S

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Cleaning-Inspection points for mostCleaning-Inspection points for most

equipmentequipment

Cleaning Grime, clogging, dust balls, rust, leakage etc.

Oils No oil, Low oil, leakage, filter clogging,dirty oil, dirty or bent oil lines, cloggeddrainage, oil spillage, worn& torn portsetc.

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equipmentequipment

Tightening Loose bolts, welding detachment,loose parts, vibration or bumpingnoise, friction

Heat Oil tanks, motors, heater, axles, controlpanels, washing/ cleaning water, bearing, wiring etc.

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equipmentequipment

Breakage, Cracks

Breakage, cracks, dent on slidingparts, handle has come off, brokenswitches, wire joints come off, wiresare broken or crack, crack dial ofvarious pre. gauges, meters etc.

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Function wise Cleaning check list ofFunction wise Cleaning check list of equipmentequipment

Pneumatics

Hydraulics

Compressed Air lines, air valves, connections, meters, filters, reservoirs etc.

Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc.

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Mach. & Power Train

Electrical

Motor fan, fan belt, couplings,Joints, pulleys, chains, pump bearings etc.

Control panel, lamps, light, switch,sensors, wiring, ducts, fuses etc.

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Tooling

EquipmentSpecific

Tools, fixtures, gauges, dies,measuring instruments, etc.

Furnaces, rollers, chutes, CNC machines, etc.

Before shine after shine

4 ‘S’

Seiketsu

4 ‘S’ – In every human being the structure of fingers are same I.e. Standardised. If it is not so, then we call it is

abnormal.

4 ‘ S’ - SEIKETSU

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SEIKETSU = SEIKETSU = StandardizationStandardizationSEIKETSU = SEIKETSU = StandardizationStandardization

Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure)

Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure)

Activity - Innovative visual management- Colour coding- Early detection of problem and early action

Success Increase in 5S indicator

Indicator

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Japanese Meaning :

Dictionary meaning

“unsoiled things, purity and cleanliness”

Clean manners ,

Clean cloths, clean politician

It is the proof that 3 S’s are being faithfully

carried out.

Japanese Meaning :

Dictionary meaning

“unsoiled things, purity and cleanliness”

Clean manners ,

Clean cloths, clean politician

It is the proof that 3 S’s are being faithfully

carried out.

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Tools used for analysis :

MTTR : Mean Time To Repair \ Recover

MTBF : Mean Time Between Failures

OEE : Overall Equipment Efficiency

Tools used for analysis :

MTTR : Mean Time To Repair \ Recover

MTBF : Mean Time Between Failures

OEE : Overall Equipment Efficiency

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Seiketsu = StandardizationSeiketsu = StandardizationSeiketsu = StandardizationSeiketsu = Standardization

• 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 3S, deploy visual management

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Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization

• 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 everybody will know that there is some problem. Visual ManagementVisual Management

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What visual control communicates ?What visual control 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

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Some methods for visual communicationSome methods for visual communication

Colour coding Use of Labels Danger alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators

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Some methods for visual communicationSome methods for visual communication

LabelsLabels Precision management labels Inspection labels Temperature labels Responsibility labels

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Points to remember in making visual Points to remember in making visual control toolscontrol tools1. Make them easy to see from distance2. Put the display on the things 3. Everyone can tell what is right and what is wrong4. Anybody can follow them and make necessary corrections easily5. Work place should look brighter & orderly

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Some everyday visual management Some everyday visual management examples examples

Traffic signal Zebra crossing In car - Petrol indicator - Speed indicator Direction arrows Electric danger sign etc.

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Some visual communication signsSome visual communication signs

5 ‘S’

Shitsuke

ENSURE . . .

Procedure & Work Instruction are correct.

Standard are expressed in specific.

Visual Aids are used.

Train at all levels.

Work ethics for effective management.

Transparent & Discipline work culture.

5 ‘S’ – Every human body has its standard process which they maintain.

5 ‘ S’ - SHITSUKE

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SHITSUKE = SHITSUKE = Self DisciplineSelf DisciplineSHITSUKE = SHITSUKE = Self DisciplineSelf Discipline

Meaning Every one sticks to the rule and makes it a habit

Meaning Every one sticks to the rule and makes it a habit

Activity - Participation of everyone in developing good habits

- Regular audits and aiming for higher level

Success High employee morale

Indicator Involvement of all people

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Japanese Meaning :

Dictionary meaning is

“learning of the manners”

“having manners, dressing neatly” OR

“training children for good customs”

Japanese Meaning :

Dictionary meaning is

“learning of the manners”

“having manners, dressing neatly” OR

“training children for good customs”

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Activities :

5S Committee

5S Training

5S Competition / evaluation

5S Month

Posters , Literature etc.

Activities :

5S Committee

5S Training

5S Competition / evaluation

5S Month

Posters , Literature etc.

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Shitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self Discipline

We need everyone to maintain 5SWe need everyone to maintain 5Sguidelines.guidelines.

To maintain DISCIPLINE, we needTo maintain DISCIPLINE, we needto practice and repeat until itto practice and repeat until itbecomes a way of life.becomes a way of life.

Discipline is the Core of 5SDiscipline is the Core of 5S

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Shitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self Discipline

Discipline means making a steadyDiscipline means making a steadyhabit of properly maintaining habit of properly maintaining correct procedurecorrect procedure.

Time and effort involved inTime and effort involved inestablishing proper arrangementestablishing proper arrangementand orderliness will be in vain if and orderliness will be in vain if we do not have discipline towe do not have discipline tomaintain it.maintain it.

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Shitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self Discipline PledgePledge

It shall be my constant effort toIt shall be my constant effort to maintain my workplace in goodmaintain my workplace in good order byorder by

Assigning a place for everythingAssigning a place for everything & keeping everything in its place& keeping everything in its place

Sorting out unwanted materialSorting out unwanted material periodically & discarding themperiodically & discarding them

Keeping my work area neat &Keeping my work area neat & clean everydayclean everyday

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Organization• Departments into areas• Coordinators at department level• Coordinator at each area level• Training for all• Audit each area and make action

check list• Implement actions• Audit and evaluation on

continuous basis

ORGANIZATION

Some 5S Examples

Before 5S

After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)

5S Pictures

Before After

5S Pictures

Before: Repair After

5S Pictures

Before After

The Good, Bad and the UglyFirst the Bad and the Ugly - Life Without 5S

The Good

THANK YOU

5S - BASIC TRAINING What is 5S and why do we want to do it? ALOK SHARMA 22\06\2010.

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Transcript of 5S - BASIC TRAINING What is 5S and why do we want to do it? ALOK SHARMA 22\06\2010.