5S Training and Implementation

7/25/2019 5S Training and Implementation

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By George Murigi


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ObjectivesObjectives

To understand the importance of 5s to our Lean

initiatives.To know what the 5Ss are and know the key

benefits of each.

Identify and overcome the barriers toproductivity

To be able to participate in group and individual

5s activities.

Improve quality of work

Practice efficiency at all times.


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5S Introduction

5S Steps

ContentsContents

5S and TPM implementation

Syndicate exercise


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IntroductionIntroduction

TPM Pillars

E

Train

Autono

Focu

Plann

A

Sa

En

TPM

rlyEquipment

anagement

ing&Educatio

n

ousMainten

ance

sedImprovem

ent

edMaintenance

ministration

ety,Health,

ironmental

Quality


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Clearing (Sort)

Organising (Set)


5S

Cleaning (Shine)

Standardising (Standardise)

Discipline (Sustain)


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5S is a system to reduce waste and optimize productivity through maintaining an orderly

workplace and using visual cues to achieve more consistent operational results.

Implementation of this method "cleans up" and organizes the workplace basically in its

existing configuration, and it is typically the first lean method which organizations implement.

The 5S pillars, Sort (Seiri), Set in Order (Seiton), Shine (Seiso), Standardize (Seiketsu), and

Sustain (Shitsuke), provide a methodology for organizing, cleaning, developing, and sustaining

a productive work environment. In the daily work of a company, routines that maintain


organization an or er iness are essentia to a smoot an e icient ow o activities. T is ean

method encourages workers to improve their working conditions and helps them to learn to

reduce waste, unplanned downtime, and in-process inventory.

A typical 5S implementation would result in significant reductions in the square footage of

space needed for existing operations. It also would result in the organization of tools and

materials into labeled and color coded storage locations, as well as "kits" that contain just what

is needed to perform a task. 5S provides the foundation on which other lean methods, such as

TPM, cellular manufacturing, just-in-time production, and six sigma can be introduced.


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Sort. Sort, the first S, focuses on eliminating unnecessary items from the workplace

that are not needed for current production operations.

An effective visual method to identify these unneeded items is called "red tagging",

which involves evaluating the necessity of each item in a work area and dealing

with it appropriately. A red tag is placed on all items that are not important for

operations or that are not in the proper location or quantity. Once the red tag items

are identified, these items are then moved to a central holding area for subsequent

dis osal rec clin or reassi nment. Or anizations often find that sortin enables

The 5S Pillars

them to reclaim valuable floor space and eliminate such things as broken tools,scrap, and excess raw material.


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Our Environmental (Generally)


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Just across the Road...


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Our Environmental (Generally)


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5S Steps5S Steps


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To do this you may need to develop a policy or fix

some rules, i.e.

Low priority items may be stored in a distant

place.

5S Steps5S Steps

Clearing

area.

The team should agree the rules and must stick to

them.

A red tag is affixed to each item that is put into the

Red Tag area.


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Stratify Strategy for Clearing (Seiri)

Separate necessary items

from unnecessary items and

discard unnecessary items.

Categorise items according

5S Steps5S Steps

,

importance, storage space

required or the place

requiring the item, for

Example, control the

categorised items

according to their type.


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Red Tag is one of the implementation plans for Sort

(seiri), part of the kaizen strategy of workplace

improvement.

A method of identifying potentially unneeded items

Red Tagging

n e wor area.

Ensures that no needed items are accidentally

disposed of.

Allows us to evaluate the usefulness of an item bysegregating it when we are unsure of its use.


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Define the necessity of the item in order to perform

the work required on a day to day basis.- If it isnt needed it should be disposed of.

Determine the fre uenc with which the item is

Red Tagging Aims

needed.- If its needed infrequently it can be stored away

from the work area.

Decide the quantity of the item required to performthe regular work.

- Excess items can be disposed or stored away.


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Sample


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Sample


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Example


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Example


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5S Steps5S Steps

After Clearing


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BeforeBefore After After


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a) Remove unnecessary items and dispose of them properly

b) Make work easier by eliminating obstacles

c) Reduce chance of being disturbed with unnecessary items

Benefits of Seiri (, sort)

d) Prevent accumulation of unnecessary items

e) Evaluate necessary items with regard to dept/cost/other

factors.


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5S Steps5S Steps


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Workplace organisation

to fix the layout of tools and equipment

everything should be readily available when

needed.

5S Steps5S Steps

Organising

Everything needed should be Easy to see, Easy

to retrieve, Easy to use, Easy to return.

4E Philosophy


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5S Steps5S Steps

Useful check points for a organised workplace:

1. Are tools divided into specialised use and regular

use items?

2. Is the number of tools required kept to a minimum?

3. Are pallets, waste bins, hoses always placed in the

Organising

4. Is anything stored around safety or fire fightingequipment?

5. Are positions of main corridors and aisles clearly

marked?6. Can you immediately and safely find the items you

need?


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5S Steps5S Steps

Organising (Examples)

5S Steps5S Steps

Visual indications to easily show

visibility of tools and equipment


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5S Steps5S Steps

Organising (One more Example)

Shadow boards for

tools


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5S Steps5S Steps

Organising (5S Cabinet - Example)

5S Steps5S Steps


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5S Steps5S Steps

After Organising


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1) Arrange all necessary items in order so they can be

easily picked for use

2) Prevent loss and waste of time

Benefits ofBenefits of SeitonSeiton ((?? ))

a e easy o n an p c up necessary ems

4) Ensure first-come-first-serve basis

5) Make work flow smooth and easy

6) Can also be translated as "set in order"

5S Steps5S Steps


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5S Steps5S Steps

38

5S Steps5S Steps


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Cleaning sounds simple enough, but it

involves a host of activities:

removing from the workplace everything

that should not be there

5S Steps5S Steps

Cleaning

ma n a n ng every ng a s ou e

there) in the best possible condition by

constant checking and constant care

Ultimately then "cleaning is careful

checking"

5S Steps5S Steps


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Before After

5S Steps5S Steps

Cleaning

5S Steps5S Steps


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5S Steps5S Steps

Cleaning Before...

Leaks all over the floor and no name

indications of the equipment

5S Steps5S Steps


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5S Steps5S StepsAfter...

Pilot equipment

5S Steps5S Steps


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Dividing zones/dividing roles

Indicate the role each person is to play (area of

responsibility)

Responsibility maps and check lists are

5S Steps5S Steps

Cleaning How to do it ?

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Implement cleaning by area/equipment

Careful and systematic cleaning of particular

areas and equipment will help spot potentialproblems

Not simply wipe off dust - Cleaning is

Inspection.

5S Steps5S Steps


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Implementing improvements

Speed up the cleaning process

Make difficult/dirty places easier to reach and

access. (DTAs)

5S Steps5S Steps


.

Defining rules for the team (Code of Conduct)

5S Steps5S Steps


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Introduce a plant slogan

Take 5 minutes for 5S

5S Steps5S Steps


Take the time to make it shine!!

5S Steps5S Steps


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pp

After Demarcating

Area of operation


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Machine reliability

- Easier to identify issues on clean machines,meaning they can be addressed sooner.

- Cleaning is a form of inspection.

Benefits of Shine

Equipment / Tools- Clean equipment functions more effectively.

- Easier to spot damage or wear on clean

equipment and tools than on dirty ones.

5S Steps5S Steps


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5S Steps5S Steps

5S Steps5S Steps


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The state that exists when the first 3 S's are

properly maintained.

make sure that clearing, organising and

cleaning are being maintained and incorporated

into everyday activities.

Standardising

identify, eliminate or take preventive action to

help prevent 3S conditions to deteriorate.

A never-ending activity!


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5S Steps5S Steps


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After StandardisingNote the exact numberof items piling up the

standard


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5S Steps5S Steps


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5S Steps5S Steps


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Defined as "making a habit of properly maintaining

correct procedures".

pp

Discipline

keep discipline?


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5S Steps5S Steps


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1. The workplace would become dirty and chaotic

again.

2. Unneeded items would soon begin piling up.

Discipline Lack of Discipline

3. People would neglect to wear their PPE and

eventually sustain an injury.

4. Equipment malfunction and defective products

5. Customers would become disgusted by our dirty

and disorganised factory.

5S Steps5S Steps


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1. Total team involvement and focus on the challenge is vital

2. Develop complete visual control to make maintaining the standards as

easy as possible Remember it's about working smarter notharder!

3. Use Fixed position photographs of before, during and after to display

your efforts.

Discipline Important Hints

4. Use specific audits to evaluate your 5S effectiveness

5S Steps5S Steps

B ildi th Di i li


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Building the Discipline

Provide activity boards

for performance follow up

5S Steps5S Steps


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Discipline Activity Board (Example)

Activity Board - 5S

TEAM

5S Progress

5S

VISION AUDIT SHEET

AUDIT PLAN ACTION

PLAN

TAGS

CONTROL

ACTION

PLAN

ACTION

PLAN

ACTION

PLAN

ACTION

PLAN

TAGS

CONTROL

TAGS

CONTROL

TAGS

CONTROL

TAGS

CONTROL

5S

MISSION

OBJECTIVES

LAY OUT

IMPLEMENTATION

PLAN

5s Radar Chart OPL

OPL

OPL

OPL

OPL

OPL

OPL

STANDARD

BENEFITS

OPL

OPL

BENEFITS BENEFITS BENEFITS BENEFITSTOTAL TAGS

PROGRESS


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Hints on 5S implementation


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Select a Pilot area for 5s

Document the current situation. Photograph Conduct a Risk Assessment

5S Hints to start up

Establish resources required Plan the approach and communicate

Share equally the responsibilities

Monitor via auditing Measure the benefits

Hints on 5S implementation


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5S Hints to start up

...

Improve!!



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10

12

Continuous

im rovements

Waste & loss

Programme

Training Autonomous

Maintenance

Safety &

p

0

2

4

6

Time

FactoryGoals Effective

Maintenance

Environment

TPM in

Administration

5 S5 S



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S

afetyandEn

Contin

uousImprov

EffectiveMaintenance

p

vir

on.

e.

A

utonomousMain

t.

TPMinAd

ministration

Training

5S implementation5S by Teams


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5S by Teams Using the sophisticated equipment supplied and the

materials (e.g.: radar, audit sheet, typical activity board,etc)

available be inventive, imaginative, resourceful in

demonstrating:

Clearing, Organising, Cleaning,

Standardising & Discipline(Seiri, Seiso, Seiton Seiketsu and Shitsuke)

Where: YOUR Syndicate Room

Important NoteImportant Note

Remember that 5s needs to be applied during the 2 weeks


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5S Training and Implementation

Documents

Transcript of 5S Training and Implementation