5S5S

PREPARED BY:PREPARED BY:

WALI UL ISALM HASHMIWALI UL ISALM HASHMIINTERNEE - PRODUCTIONINTERNEE - PRODUCTION

5S5S

5S stands for five Japanese words5S stands for five Japanese words

EISOU – CLEANING

EIRI – ARRANGEMENT

EITON – ORDERLINESS

EIKETSU – NEATNESS

HITSUKE – HABITS

what is 5S?what is 5S?

5S is a method for organizing a workplace, especially a 5S is a method for organizing a workplace, especially a sharedshared workplace (like a shop floor or an office space), and keeping it workplace (like a shop floor or an office space), and keeping it organized. organized.

The key targets of 5S are workplace morale and efficiency.The key targets of 5S are workplace morale and efficiency.

what is 5S?what is 5S?

benefits of this methodology come from deciding benefits of this methodology come from deciding whatwhat should be should be kept, kept, wherewhere It should be kept, and It should be kept, and howhow it should be stored. it should be stored.

The implementation of 5S is by assigning everything a location The implementation of 5S is by assigning everything a location so time is not wasted by looking for things.so time is not wasted by looking for things.

SEIRISEIRI - ARRANGEMENT - ARRANGEMENT

SEIRI means “ arranging exactly what we SEIRI means “ arranging exactly what we need effectively”need effectively”

SEIRI involves going through all the SEIRI involves going through all the tools, materials, etc., in the plant and tools, materials, etc., in the plant and work area and keeping only essential work area and keeping only essential items. Everything else is stored or items. Everything else is stored or discarded discarded

PRINCIPLES OF PRINCIPLES OF SEIRISEIRI

CLASSIFICATION:CLASSIFICATION: Classification of necessary items on the basis of Classification of necessary items on the basis of

function and frequency of usefunction and frequency of use

ELIMINATION:ELIMINATION: Removing all un necessary itemsRemoving all un necessary items

APPROPRIATE STORAGE:APPROPRIATE STORAGE: All necessary items are stored at appropriate All necessary items are stored at appropriate

locations so they are readily accessible when locations so they are readily accessible when neededneeded

BENEFITS OF BENEFITS OF SEIRISEIRI

Stock reductionStock reduction

Space availabilitySpace availability

Less accidents due to space availabilityLess accidents due to space availability

SEITONSEITON - ORDERLINESS - ORDERLINESS

SEITON means orderliness or proper SEITON means orderliness or proper arrangementarrangement

PURPOSE:PURPOSE: A place for everything and everything in its A place for everything and everything in its

placeplace Functional storage to increase efficiencyFunctional storage to increase efficiency Eliminate search timeEliminate search time

PRINCIPLES OF PRINCIPLES OF SEITONSEITON

A PLACE OF EVERYTHING:A PLACE OF EVERYTHING: All tools are placed in specified places as per All tools are placed in specified places as per

standardized quantities such as hardware bin, rack, standardized quantities such as hardware bin, rack, pallets etc.pallets etc.

The storage should be considered on the basis of The storage should be considered on the basis of ergonomicsergonomics

MATCHING THE PRODUCTION FLOWMATCHING THE PRODUCTION FLOW:: Storage should be designed on the basis of Storage should be designed on the basis of

production flow. For example hanging tools and production flow. For example hanging tools and moving trolleys can reduce walking timemoving trolleys can reduce walking time

BENEFITS OF BENEFITS OF SEITONSEITON

Increased whole efficiencyIncreased whole efficiency

Avoiding mistakesAvoiding mistakes

Improved safetyImproved safety

SEISOSEISO - CLEANING - CLEANING

SEISO means “Cleaning”SEISO means “Cleaning”

It involves the need to keep the workplace clean as It involves the need to keep the workplace clean as well as neat. well as neat.

The key point is that maintaining cleanliness should be The key point is that maintaining cleanliness should be part of the daily work - not an occasional activity part of the daily work - not an occasional activity initiated when things get too messy. initiated when things get too messy.

Includes daily activity at the end of each shift, the work Includes daily activity at the end of each shift, the work area is cleaned up and everything is restored to its area is cleaned up and everything is restored to its placeplace

ELEMENTS OF ELEMENTS OF SEISOSEISO

The meaning of cleaning is:The meaning of cleaning is:

checking or inspectionchecking or inspection To find the source of dirt and eliminate itTo find the source of dirt and eliminate it To always maintain a clean environmentTo always maintain a clean environment

BENEFITS OF BENEFITS OF SEISOSEISO

Increase in work efficiencyIncrease in work efficiency

Safety ImprovementSafety Improvement

SEIKETSU SEIKETSU - NEATNESS- NEATNESS

SEIKETSU means standardization or SEIKETSU means standardization or applying the first three principles of 5S applying the first three principles of 5S and maintaining themand maintaining them

PURPOSE:PURPOSE: To maintain a clean and trouble free work To maintain a clean and trouble free work

placeplace

PRINCIPLES OF PRINCIPLES OF SEIKETSUSEIKETSU

TO CREATE COMMON RULES FOR TO CREATE COMMON RULES FOR STANDARDIZATION:STANDARDIZATION: Make lists of standardized items by color coding, Make lists of standardized items by color coding,

labeling and standardization counter measurelabeling and standardization counter measure

VISUAL MANAGEMENT:VISUAL MANAGEMENT: Visual control to reveal abnormalities such as Visual control to reveal abnormalities such as

direction of flow, indication on valves for open or direction of flow, indication on valves for open or close, green painted walkway on a factory floor to close, green painted walkway on a factory floor to show the walking track for peopleshow the walking track for people

BENEFITS OF BENEFITS OF SEIKETSUSEIKETSU

Effective visual controlEffective visual control Increased work efficiencyIncreased work efficiency Reduced cleaning timeReduced cleaning time Improved whole environmentImproved whole environment

SHITSUKESHITSUKE - HABITS - HABITS

SHITSUKE means sustaining SHITSUKE means sustaining

Includes maintaining and reviewing standardsIncludes maintaining and reviewing standards

Once the previous 4S's have been established Once the previous 4S's have been established they become the new way to operate. they become the new way to operate.

Maintain the focus on this new way of Maintain the focus on this new way of operating, and do not allow a gradual decline operating, and do not allow a gradual decline back to the old ways of operating. back to the old ways of operating.

ELEMENTS OF SHITSUKEELEMENTS OF SHITSUKE

CREATING THE REASONABLE RULES OF CREATING THE REASONABLE RULES OF THE GAME:THE GAME: To create the reasonable rules of the game and To create the reasonable rules of the game and

should be displayed clearlyshould be displayed clearly

PRACTICE MAKES PERFECT:PRACTICE MAKES PERFECT: Repetition of movement such as simulation training, Repetition of movement such as simulation training,

bolt or screw tightening on practice board etc.bolt or screw tightening on practice board etc.

MAKING HABITUAL:MAKING HABITUAL: Habit development through internalizing the rulesHabit development through internalizing the rules

BENEFITS OF SHITSUKEBENEFITS OF SHITSUKE

Better mutual understanding and team Better mutual understanding and team workwork

Better confidence, autonomy and Better confidence, autonomy and efficiency improvementefficiency improvement

ADVANTAGES OF ADVANTAGES OF IMPLEMENTING 5SIMPLEMENTING 5S

SAFETYSAFETY All items are visibleAll items are visible Potential safety hazards labeledPotential safety hazards labeled Less congestionLess congestion

NEATNESSNEATNESS Orderly arrangementOrderly arrangement SystematicSystematic Only needed itemsOnly needed items

LESS FATIGUELESS FATIGUE No unnecessary movementNo unnecessary movement Reduce needed movementReduce needed movement Reduce distance of movementReduce distance of movement

FASTERFASTER Easy identificationEasy identification Within reachWithin reach No need to reach for itemsNo need to reach for items Anyone can understand the work placeAnyone can understand the work place

QUALITYQUALITY Better product qualityBetter product quality Consistent qualityConsistent quality Barrier equipment maintenanceBarrier equipment maintenance Positive customer perceptionPositive customer perception