5S Training Slides

Seiri

Seiton

Seiketsu

Seiso

Shitsuke

1980198019501950 1970197019601960

U.S.AU.S.AJAPANJAPAN

INDIAINDIA

Quality ImprovementsQuality Improvements

1. 5S Principles

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

operative effortoperative effort Attack root causeAttack root cause Human being is not infalliableHuman being is not infalliable

2. Objectives

Improve housekeepingImprove housekeeping Make every individual Make every individual

responsible for housekeepingresponsible for housekeeping Beautify by simple meansBeautify by simple means Productivity improvement by Productivity improvement by

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

3. 5S’s

•SeiriSeiri - Sorting- Sorting

•Seiton Seiton - Systematic arrangement- Systematic arrangement

•Seiso Seiso - Cleaning - Cleaning Inspection while cleaning Inspection while cleaning

•SeiketsuSeiketsu - Standardization- Standardization

•ShitsukeShitsuke - Self Discipline- Self Discipline

5S

If we do not do 5S, we can’t do anyother work efficiently. They are features which are common to all places and are the indicators of how well an organization is functioning.

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

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

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 zoneAVER

AG

E

HIGH *Things used once a week Store near the workplace

*Things used daily or hourly Store near the workplace

Organization

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..


2. Tools, Toolings, 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..


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..


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

Seiri = SortingSeiri = Sorting Improvement methods

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

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

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

Seiri = SortingSeiri = Sorting Dealing with papers

How to reduce papers on your table ?

4 D Principle4 D Principle

DODELEGATEDELAYDUMP

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

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

The main target areas for Seri-Seiton improvement are :

Tool-setting and preparation operations, line balancing and process planning, parts supply to assembly line, peak time problems etc.

Improvement Methods

Kit Method / Assembly box method / Outside tool setting

Cassettisation / Parallel operations / Changes in assignment method

The main target areas for Seri-Seiton improvement are :

Tool-setting and preparation operations, line balancing and process planning, parts supply to assembly line, peak time problems etc.

Improvement Methods

Kit Method / Assembly box method / Outside tool setting

Cassettisation / Parallel operations / Changes in assignment method

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


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..


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


USE :USE :

1 ) Signboards1 ) Signboards

2) Colour codes2) Colour codes

3) Outline markings3) Outline markings

4) Labels4) Labels


FunctionalFunctional

StorageStorage


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


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

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

Functional Storage


• 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


• 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


• 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


• 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

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

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


Various Minor DefectsVarious Minor Defects= Trash = Dirt =Knocking = Loose parts = Leaks =Scattering=Skips =Curvature =Abrasion=Rust =Scratches =Eccentricity=Lurching =Abnormal =Vibration

Movements=Abnormal =Heat =Abnormal Sounds smells=Faded colour =Hisses


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


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.



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

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



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.


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.



Mech & Power Train

Electrical

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

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



Toolings

EquipmentSpecific

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

Furnaces, rollers, chutes, CNC machines, etc.

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

SEIKETSU = SEIKETSU = StandardizationStandardizationSEIKETSU = SEIKETSU = StandardizationStandardization

Tools used for analysis :

MTTR

MTBF

OEE

Tools used for analysis :

MTTR

MTBF

OEE

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

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


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


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


Some methods for visual communicationSome methods for visual communication

LabelsLabels Precision management labels Inspection labels Temperature labels Responsibility labels


Points to remember in making visual cPoints to remember in making visual ccontrol 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


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.


Some visual communication signsSome visual communication signs

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

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

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.

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

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.

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

Heat Treatment Area in JapanHeat Treatment Area in JapanHeat Treatment Area in JapanHeat Treatment Area in Japan

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