5s(bang)

S.B.Shinde -- Sourcing Quality AssuranceSeiriSeitonSeisoSeiketsuShitsukeAsao svacCta ijaqao ijaqao vasao laxmaI itqao itqao

S.B.Shinde -- Sourcing Quality Assurance

S.B.Shinde -- Sourcing Quality Assurance1980195019701960U.S.AJAPANINDIAQuality Improvements


S.B.Shinde -- Sourcing Quality Assurance1. 5S Principles Elimination of waste Every body is involved, Co-operative effort Attack root cause Human being is not infalliable


S.B.Shinde -- Sourcing Quality Assurance2. Objectives Improve housekeeping Make every individual responsible for housekeeping Beautify by simple means Productivity improvement by saving time, space etc.


S.B.Shinde -- Sourcing Quality Assurance3. 5SsSeiri - SortingSeiton - Systematic arrangementSeiso - Cleaning Inspection while cleaningSeiketsu - StandardizationShitsuke - Self Discipline


S.B.Shinde -- Sourcing Quality Assurance5SIf we do not do 5S, we cant do anyother work efficiently. They are features which are common to all places and are the indicators of how well an organization is functioning.


S.B.Shinde -- Sourcing Quality AssuranceSEIRI = SortingMeaningDistinguish between necessary and unnecessary items and eliminate the unnecessary items

ActivityEstablish a criteria for eliminating unwanted itemsEliminate unwanted items either by disposing them or by relocating them.SuccessArea saved or percentage of space availableIndicator


S.B.Shinde -- Sourcing Quality Assurance1. 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 partsSeiri = SortingWhat is unnecessary


S.B.Shinde -- Sourcing Quality Assurance Frequency of useStorage Method*Things you have not used in the past one yearThrow them out*Things you have used once in the last 6-12 months Store at distance OR Keep in storeLOW*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 zoneAVERAGE

HIGH*Things used once a week Store near the workplace*Things used daily or hourly Store near the workplaceOrganization


S.B.Shinde -- Sourcing Quality AssuranceSeiri = SortingIdentifying unnecessary1. 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 useContd..


S.B.Shinde -- Sourcing Quality AssuranceSeiri = SortingIdentifying unnecessary2. 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 useContd..


S.B.Shinde -- Sourcing Quality AssuranceSeiri = SortingIdentifying unnecessary4. 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..


S.B.Shinde -- Sourcing Quality AssuranceSeiri = SortingIdentifying unnecessary8.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


S.B.Shinde -- Sourcing Quality AssuranceSeiri = SortingImprovement methods1. 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.


S.B.Shinde -- Sourcing Quality AssuranceSeiri = SortingDealing with papersHow to reduce papers on your table ?1. Make a single pile of papers2. Go through them and sort in following categoriesa) Immediate actionb) Low priorityc) Pendingd) Reading materiale) For information


S.B.Shinde -- Sourcing Quality AssuranceSeiri = SortingDealing with papersHow to reduce papers on your table ?4 D Principle

DODELEGATEDELAYDUMP


S.B.Shinde -- Sourcing Quality AssuranceSEITION = Systematic Arrangement MeaningTo 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 placeSuccess- Time saved in searching Indicator - Time saved in material handling


S.B.Shinde -- Sourcing Quality AssuranceSEITION = Systematic ArrangementThe 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 MethodsKit Method / Assembly box method / Outside tool setting Cassettisation / Parallel operations / Changes in assignment method


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic ArrangementHow to achieve Systematic Arrangement ?

Decide where things belong

Decide how things should be put away

Obey the Put away rules


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic ArrangementHow 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..


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic ArrangementHow 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


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic ArrangementUSE :

1 ) Signboards

2) Colour codes

3) Outline markings

4) Labels


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic ArrangementFunctionalStorage


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic ArrangementUsageFrequency Store frequently used material near the workplace and less frequently at some distanceWeight &Shape of theMaterial Heavy material should be stored at lower levels/layers Place directly on the material handling device for ease of handlingFunctional Storage


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic ArrangementCategory Same category of material may be stored in one location. Eg. Allen Screws, Oil Seals OperationWise All items required for an operation may be stored in one location. Eg. Allen key, spanner etc hand tools required for setting m/cFunctional Storage


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic Arrangement 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


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic Arrangement 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


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic Arrangement 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


S.B.Shinde -- Sourcing Quality AssuranceSeiton = Systematic Arrangement 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


S.B.Shinde -- Sourcing Quality AssuranceSEISO = Cleaning MeaningCleaning trash, filth, dust and other foreign matter. Cleaning as a form of InspectionActivity- Keep workplace spotlessly clean- Inspection while cleaning- Finding minor problems with cleaning inspectionSuccess- Reduction in machine down timeIndicator - Reduction in no. of accidents


S.B.Shinde -- Sourcing Quality AssuranceSeiso = Cleaning

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

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


S.B.Shinde -- Sourcing Quality AssuranceSeiso = CleaningVarious 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


S.B.Shinde -- Sourcing Quality AssuranceSeiso = Cleaning

5 Minutes Every day for cleaning

Devote 5 minutes everyday for cleaning your work area

Participation of everyone is required

Attack hard to clean places regularly


S.B.Shinde -- Sourcing Quality AssuranceSeiso = Cleaning Cleaning-Inspection points for most equipment CleaningGrime, clogging, dust balls, rust, leakage etc.OilsNo oil, Low oil, leakage, filter clogging,dirty oil, dirty or bent oil lines, cloggeddrainage, oil spillage, worn& torn portsetc.


S.B.Shinde -- Sourcing Quality AssuranceSeiso = Cleaning Cleaning-Inspection points for most equipment TighteningLoose bolts, welding detachment,loose parts, vibration or bumpingnoise, friction HeatOil tanks, motors, heater, axles, controlpanels, washing/ cleaning water, bearing, wiring etc.


S.B.Shinde -- Sourcing Quality AssuranceSeiso = Cleaning Cleaning-Inspection points for most equipment Breakage, CracksBreakage, cracks, dent on slidingparts, handle has come off, brokenswitches, wire joints come off, wiresare broken or crack, crack dial ofvarious pre. gauges, meters etc.


S.B.Shinde -- Sourcing Quality AssuranceSeiso = Cleaning Function wise Cleaning check list of equipmentPneumatics HydraulicsCompressed Air lines, air valves, connections, meters, filters, reservoirs etc.Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc.


S.B.Shinde -- Sourcing Quality AssuranceSeiso = Cleaning Function wise Cleaning check list of equipmentMech & Power Train ElectricalMotor fan, fan belt, couplings,Joints, pulleys, chains, pump bearings etc.Control panel, lamps, light, switch,sensors, wiring, ducts, fuses etc.


S.B.Shinde -- Sourcing Quality AssuranceSeiso = Cleaning Function wise Cleaning check list of equipmentToolingsEquipmentSpecificTools, fixtures, gauges, dies,measuring instruments, etc.Furnaces, rollers, chutes, CNC machines, etc.


S.B.Shinde -- Sourcing Quality AssuranceSEIKETSU = StandardizationMeaningSetting 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 actionSuccessIncrease in 5S indicatorIndicator


S.B.Shinde -- Sourcing Quality AssuranceSEIKETSU = StandardizationTools used for analysis :MTTRMTBFOEE


S.B.Shinde -- Sourcing Quality AssuranceSeiketsu = 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


S.B.Shinde -- Sourcing Quality AssuranceSeiketsu = 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 Management


S.B.Shinde -- Sourcing Quality AssuranceSeiketsu = Standardization 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


S.B.Shinde -- Sourcing Quality AssuranceSeiketsu = Standardization Some methods for visual communication

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


S.B.Shinde -- Sourcing Quality AssuranceSeiketsu = Standardization Some methods for visual communication

Labels Precision management labels Inspection labels Temperature labels Responsibility labels


S.B.Shinde -- Sourcing Quality AssuranceSeiketsu = Standardization Points to remember in making visual ccontrol 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


S.B.Shinde -- Sourcing Quality AssuranceSeiketsu = Standardization Some everyday visual management examples Traffic signal Zebra crossing In car - Petrol indicator - Speed indicator Direction arrows Electric danger sign etc.


S.B.Shinde -- Sourcing Quality AssuranceSeiketsu = Standardization Some visual communication signs


S.B.Shinde -- Sourcing Quality AssuranceSHITSUKE = Self DisciplineMeaningEvery 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 moraleIndicator Involvement of all people


S.B.Shinde -- Sourcing Quality AssuranceSHITSUKE = Self DisciplineActivities :5S Committee5S Training5S Competition / evaluation5S MonthPosters , Literature etc.


S.B.Shinde -- Sourcing Quality AssuranceShitsuke = Self Discipline

We need everyone to maintain 5Sguidelines.

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

Discipline is the Core of 5S


S.B.Shinde -- Sourcing Quality AssuranceShitsuke = Self DisciplineDiscipline means making a steadyhabit of properly maintaining correct procedure.

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


S.B.Shinde -- Sourcing Quality AssuranceShitsuke = Self DisciplinePledge It shall be my constant effort to maintain my workplace in good order by Assigning a place for everything & keeping everything in its place Sorting out unwanted material periodically & discarding them Keeping my work area neat & clean everyday


S.B.Shinde -- Sourcing Quality AssuranceHeat Treatment Area in Japan


S.B.Shinde -- Sourcing Quality AssuranceHeat Treatment Area in Japan


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