FIRST CHALLENGE FIRST CHALLENGE ONON

Welcome to

5’S’

Program

About 5SA cornerstone of 5’S is that :

untidy, cluttered work/study areas are not productive.

People are happier :In a clean and tidy environment and hence are inclined to work hard with due care and attention.

WHY DO IT?QUALITY EFFICIENCY

SAFETY ELIMINATING BREAKDOWNS

5’S

QUALITYQUALITYHelps to build a quality work

environment.Designs the workplace both

physically and mentally.Better asset utilization.Lower defect rates.

EFFICIENCYTime is wasted looking for tools,

equipment and appliances , cutleries, etc.

A clean and tidy workplace leads to

greater well being and increased

motivation.

Team working makes unexciting work

more rewarding.

ELIMINATE BREAKDOWNS

Breakdowns caused by the elimination of dirt need never occur.

Clear labelling and routine maintenance are essential disciplines.

A clean workplace highlights problems early.

SAFETYDirty cluttered workplaces are

not safe.

Safety depends on good care and organisation.

Safety should become second nature.

The Changing ScenarioCustomer ExpectationsProduct Quality PerceptionsEmployee & Employers’

expectationsCompetitionGovernment Rules &

Regulations- Liberalization

In this changing scenario, we must change:Our way of thinking

Our way of working

What is Canteen kitchen

A canteen is a place in a factory , shop or college

where meals are served to the people who work or

study there.

5’SBACKGROUND

Since the early 80’s Japanese industries widely practiced 5S as a powerful technique to improve productivity and quality.

Today, 5 S is used worldwide to prepare the ground for improvement

Levels of canteen kitchenFollowing the 5 S principles

and reducing wasteExtending the 5 S concept

to include ergonomicsExtending the 5 S concept

to include aestheticsMaintaining records and

educating others

Do these points describe your company work areas?

Space is crowded with parts and tools. Unneeded items are stacked between

workers Excess inventory on the floor. Excess items and appliances make it

difficult to improve process flow. Equipment is dirty and a collection

point for miscellaneous materials. Needed equipment such as cutleries

are difficult to find.

Elements of 5’SComprises of 5 simple steps:1. SEIRI - Sorting Out2. SEITON - Systematic

arrangement3. SEISO - Spic and Span4. SEIKETSU - Standardization5. SHITSUKE - Self Discipline

SORTING-Step 1Segregating necessary from unnecessary and throwing away what is not required at all.

(Done with the objective of saving and recovering

space)

SORTINGSegregating necessary from

unnecessaryDiscarding what is not

requiredDeciding on a frequency of

sortingAll tools , gauges , materials ,

classified and stored.

BEFORE AFTER

Specific Objectives-SORT

PRIORITY FREQUENCY OF USE HOW TO USE

Low Less than once per year

Once per year

•Throw away•Store away from the workplace

Average At least 2/6 months

Once per month

Once per week

Store together but offline

High Once Per Day Locate at the workplace

Identify & sort to segregate usable from

non-usable items

U sab le Item

R ework

R eworkab le

D iscard

R e jec ted

S C R A P

U sab le Item

R ep a ir

R ep a irab le

D iscard

U n rep a irab le

N ecessary

D iscard

N o P oten tia l U se

U sab le Item

M ove to R eqL oca tion

P oten tia lly U se fu l

D iscard

A rran g eD isp osa l

R eq S p l D isp osa l

U n n ecessary

N O T IN W O R K IN G O R D E R

U sab le Item

IN W O R K IN G O R D E R

S O R TIN G

What do you sort? & How Often?

Stainless steelGreat sinkHigh performance appliances

Integrated refrigerationNatural lightA hook

SYSTEMATIC SYSTEMATIC ARRANGEMENTARRANGEMENT

STEP II - Systematic

ArrangementA rational, orderly and

methodical arrangement

of all items we use, re-

work or write off

Systematic ArrangementPutting things in order after

Analyzing whyGetting things out and putting

them back takes so long

(Done with the objective of minimizing search time and errors)

Specific Objectives - SYSTEMATIZE

Organise layout of tools and appliances :Designated locations.Use tapes and labels.

Ensure everything is available as it is needed and at the “point of use”.

A place for everything and everything on itsplace."

Having a place for everything &

everything in its place (canteen kitchen)

Prevent cutleries from getting cluttered. Categorization of ingredients,utensils, etc. Compartmentalization of desk drawers/

shelves/cabinets. Designating responsibilities for crockery in

shared use. Prioritizing the things to do - planning a

sequence Labeling/identifying drawers Color coding Decide `how much’ of what is needed

Categorizing of Canteen KitchenBy cooking

By food items

By manufacturing materials

By pricing

By brand names

By customer

SPIC AND SPAN

Understanding how to prevent things from getting dirty and ensuring tip top condition

(Done with the objective of inspecting for problems and

taking faster corrective actions)

Specific Objectives- SWEEP, SHINE, SCRUB

Create a spotless workplace

Identify and eliminate causes of dirt and grime – remove the need to clean

Sweep, dust, polish and paint

SPIC AND SPAN

Steps to be followed during or after major housekeeping

Do a survey of the origins of grime & Leakage

Set priorities for cleaning where grime is most

study why things are dirty study possible plan of action Decide on action steps/ responsibility/

timeframe

Ensuring cleanliness and tiptop conditions

Type of grime in kitchenDustDirt

WaterFittings

TemperatureLitter

SPIC AND SPANIf there’s Lesser number of

items, there is lesser to cleanOne is best :

One one day processingone location of cutleriesone copy filing

STEP IV - STEP IV - STANDARDIZATIONSTANDARDIZATION

Following of earlier 3 S’s, standardized work procedures, maintaining safe & hygienic conditions in work place of kitchen contribute to a serene atmosphere

Standards for My kitchen-Product & Processes

My appliances My work area

Specific ObjectivesSTANDARDIZE

Standardize clean-up activities by: Sustaining five-minute daily clean

up habit. Keeping a balance between

personal. cleanliness and the cleanliness of

the environment / work place. Avoiding littering. Learning to pick-

up tiny pieces of waste around.

STANDARDIZATION

Ensuring conducive and

safe working Environment

(Done with the objective of Achieving higher productivity

and better quality through higher employee morale)

SELF DISCIPLINE

Training, Evaluation and

Follow-up Actions

(Done with the objective of Achieving constancy of Purpose)

Specific ObjectivesSELF-DISCIPLINE

Instilling the ability of doing things. the way they are supposed to be

done. Becoming a role model by treating. your work place as your second

home. Influencing others to join in keeping. a well-maintained work place. Aiming for constant improvement.

A bad example of discipline

SELF DISCIPLINESELF DISCIPLINE Introduce 3 min 5 S activity system How often Introduce 5 S Activity Evaluation

system Train Evaluators Train Implementers on Problem solving steps What defects to look for Preparing and using

implementation checklist

5’S EvaluationWhat is it? An activity or related activities to

determine whether there is an existence of a system & the system is in operation as per established norms. It also verifies whether the system & results are taking the organization towards the desired objectives.

Attributes of an EvaluatorAttributes of an Evaluator

One who believes in 5 SStrict, Fair and TactfulMust be able to do it in an

competent mannerWilling to go to the workplace,

offer advice and point out problems when necessary

Should be able to comment on successes and shortcomings clearly

Implementing 5S-Methodology

Working environment of shop floor will be healthy.

Safety will be enhance.Environment pollution reduced.Productivity increase and down time

will be reduced.Product quality will be good and

high.Profit will increase.Morale of employer will be high.

BENEFITS Improvements in:-

Workforce morale

Canteen image

Health and Safety

Appliances maintenance

Quality

ProductivityLeading to Increased Competitiveness

Advantages of 5’SNice to work in a clean, beautiful,

organized workplace of kitchen.Time taken to reach things

minimized.Lesser time wasted in information

handling.Problems detected fast.Customer Response time reduced.More usable space.

Advantages contd... Better preventive maintenance.

Higher employee involvement. Reduction in errors/defects due to

standardized procedures. Consistent & better customer

handling. Higher productivity. Higher employee morale. More time for improvement

activities.

Preventative actions Preventative actions

When a problem keeps occurring you need to put into place actions to solve them. Do not simply keep dealing with the symptoms, you need to find the cause.

Why do tools get put back in the wrong place?

Why do items accumulate? Why are the floors getting dirty? etc. When you ask WHY repeatedly you will

find the problem.

5S OR 5D…?If 5S is not taken up seriously, then it

leads to 5D.  They are

Delays, Defects, Dissatisfied customers, Declining profits and Demoralized employees.

5 ‘S is 5 ‘S is TRANSFORMATIONTRANSFORMATION

“If we fail to improve 5’S, what makes us think that we can do anything else?”

On the other hand we know that if we can do 5 S, we can do anything. 5 S is fundamental, so it gives us the power to build out capabilities to meet the BIG CHALLENGES. That is why 5 S is transformational’.

THANK YOU MADE BY:

NISHA VERMA NIKITA

SHREYA GUPTA (B.COM

2nd year….)