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Transcript of 5s Presentation
Quality Assurance
Necessity of 5S
SEIRI
SEITON SEIKETSUSEISOU
SHITSUKE
Productivity improvement
Quality assurance Cost reduction
Secure production volume
Deadline observation Happy workplace
Job satisfaction
Workplace improvementWorkplace improvement
Quality Assurance
Definition of 5S
(1) SEIRI (Sort)Distinguishing between necessary and unnecessary things, and getting rid of what you do not need
(2) SEITON (Set in Order)The practice of orderly storage so the right item can be picked efficiently (without waste) at the right time
(3) SEISOU(Shine)Create a clean worksite without garbage and dust
(4) SEIKETSU(Standardization)Standardization of best practices
(5) SHITSUKE (Sustain) The practice of developing customs so that the workplace regulations and rules are
correctly practiced
Quality Assurance
Promotion of 5S
(1)
SEIRI(Sort)
Dispose what is not needed
(2)
SEITON(set in order)
Can retrieve when required
(3) SEISOU
(Shine)
Make the workplace clean
(4)SEIKETSU (Standard)Standardized the
solution
(5)
SHITSUKE(Discipline)
Develop customs that allow practice of regulations and rules
Quality Assurance
Objective of 5S
Remove wasteRemove waste
Implement so that ‘waste becomes visible
to facilitate waste removal’
Waste = Current work – money generating workFrom current work remove work that does not generate money
Quality Assurance
5S that Eliminates Waste
Clean
objects Dirty
objects Clean
objects
A little dirty
objects
Dirty objects
Waste (rag) sifting boxes
Quality Assurance
“Self-discipline” is the foundation for success of 5S
““Self-discipline” supports 5SSelf-discipline” supports 5S
Seiketsu(Standardization)
Seiso(Shine)
Seiri(Sort)
Seiton(Set in order)
Sitsuke (Sustain )
Quality Assurance
Heinrich’s Law
Major accident
1 incident
Small scale accidents
29 incidents
Near miss / startling incidents
300 incidents
Accumulation of small details leads to big success
Quality Assurance
StandardizationStandardization
Bolts Sifting and Sorting
Normal 5S
Profitable 5SProfitable 5S
What value is being created ?What value is being created ?
Quality Assurance
SEIRI
Dispose Assign fixed place
SEIRI (Sort) refers to:
Distinguishing between necessary things and unnecessary things and getting rid of what you
do not need
Stratify
Steps
Quality Assurance
Stratification
‘Stratification’ refers to:Assorting things around oneself into those that are required and those that are not required
*Other than things used daily are non-required things
*Quantity in excess of what is used daily is non-required * ‘Leave only this, just in case’ is strictly prohibited
Quality Assurance
Action Standards
Standards Action
Dispose
Things used approximately once in 6 to 12 months Place far away
Things used approximately once in 1 to 6 monthsGather and place together at the worksite
Things used once a week Place in vicinity of work
Things used daily
Place so that they are easy to pickMake it easy to return
Identifiable
Things used every hourPlace within arm’s length where they can be easily reached
Quality Assurance
Categorization of Actions
Category Candidate items for actions
Product, in-process product, components, materials, sub-materials etc.
Machinery, jigs, tools, molds etc.
Old products, components, materials, sub-materials etc.
Drawings, documents, magazines, catalogs etc.
Those that have expiredNon-required items
Those that have become old
Damaged products, non-conforming products, rusted
materials etc.
Things not planned to be used
Things not used for several years
Quality Assurance
Assign Fixed Places
Assigning fixed places refers to:Preparing rules and making visible ‘where’ and in ‘what quantity’’ the required things are to be placed
* Decide locations for things that will remain
* Make rules for locations
* Making visible refers to visual management * Start with what can be done
Quality Assurance
Location of things that will remain
Location of things that will remain should
consider :
(1) Where it will be used
(2) Where it will be placed
(3) How much it will be placed
(4) How it will be placed
Quality Assurance
SEITON
Make it compact
SEITON (Set in order) refers to :Implementing functional storage by deciding correct placement method and layout so that the required objects can be quickly used what it is required
Assign fixed places and fixed quantity
Steps
Quality Assurance
Assign fixed places and fixed quantity
Assigning fixed places and fixed quantity :Refers to facilitating picking and placing and ensuring zero shortages
* Give priority to use frequency and decide fixed place
* Consider also safety (mainly weight) -Place heavy objects at a height where they are easy to pick from
* Eliminate labor required for searching and returning
* Decide placing volume bused on usage volume (1 time, 1 day)
Quality Assurance
Storage Index
Storage index = Steps x Hand operation frequency
* How many steps does it take to walk to the storage
location?
* How many times is it necessary to move the hand to
grip, transport and place the object for storage?
*The storage coefficient will vary according to holding
method, transporting method and placement method
Quality Assurance
Decision standards for fixed positions
(1) Where it will be used Clarification of usage objective and place
(2) Where it will be placedNear where it will be used so that work can be done while walkingStand-up operations
(3) How much will be placed Maximum, Minimum, Order point
(4) How will it be placedEasy to place, Easy to remove (one-touch operation)
(5) Indication of placing location Coloring, boundaries
(6) Recognize visuallyIllustrative indication, component name indication, Quantity indication
(7) Stagnating time is visibleFirst in- First out, Recognize by observing placement date
(8)Decide person in-charge of
supervisionIndicate person responsible
Quality Assurance
Examples of tools sorting (Seiton)
Quality Assurance
SEISO
Take action to prevent dirtiness and its occurrence
SEISO (Shine) refers to :Removal of dirt and by investigating source of dirt preparing countermeasures
Identify source of occurrence
Steps
Quality Assurance
Take Preventive Actions
Actions to prevent dirtiness and its occurrence refers to: countermeasures against source of occurrence include countermeasures (challenge towards common sense) for process methods (defects in processing conditions etc.)
*The basic point is sweeping and cleaning and inspecting
*It is also important to take immediate actions such as placing a cover etc.
* Accumulation of small points will lead to a situation where sweeping is not required
Quality Assurance
SEIKETSU
Make abnormalities visible in management points
SEIKETSU (Standardization ) refers to:Standardization of 5S through ‘visual management’
Grasp vital points for management
Steps
Quality Assurance
Standardization of 5S
(1)
Clarification of vital points for management- What are the minute defects- Basic conditions: Cleanliness, refueling, replace tightly bind fast, dirt,
looseness - Operating conditions: pressure, temperature, time, flow volume, weight, Equipment, jigs and tools, sub-materials
(2) Prepare standards for the conditions
- Objectification of judgment standards for normal versus abnormal- Judgment without using measurement, knowledge, intuition and knack
(3) Judgment standards for abnormalities
- Inspection methods that can be used by anybody- Methods for actions against abnormalities
Quality Assurance
Points for Visual Management
(1) Recognize well even from a distance
(2) There are indicators on items to be managed
(3) Whether good or bad is clear, and anybody can point out
(4) Anybody can use, and convenient if used
(5) Anybody can follow and repair quickly
(6) Use of tools leads to neatness
Quality Assurance
SITSUKE
Innovate to ensure observance
SITSUKE (Sustain ) refers to: Preparation of workplace atmosphere where visual management is properly observed
Check state of observance of standardization of 5S
Steps