understanding 5S

Kortek Let’s Win Customers

Understanding 5S

Presented By : ( Mr. D G Amle / Quality )Date: 12th Jun’2010


WHAT PROBLEMS DO U COMMONLY

ENCOUNTER AT YOUR WORKPLACE

HIGH ABSENTEEISM HIGH TURNOVER DEMOTIVATED EMPLOYEES DISORDERED/ CLUTTERED ENVIRONMENT MISTAKES/ERRORS


THE SOLUTION TO ALL THESE PROBLEMS IS

5S

5S Is the HOUSEKEEPING TECHNIQUE

PRODUCTIVITY AND SAFETY ENHANCEMENT TECHNIQUE


IDEA BEHIND 5SIDEA BEHIND 5S

• IN ORDER TO ACHIEVE HIGH LEVELS OF QUALITY, SAFETY AND PRODUCTIVITY, WORKERS MUST

HAVE A HEALTHY WORKING ENVIRONMENT


1. 5S Goal & Definition1. 5S Goal & Definition

2. 5S obstacle2. 5S obstacle

3. Fixation point3. Fixation point

4. Expectation effect4. Expectation effect

5. Details 5. Details

1)Sort(SEIRI) 2)Set In Order (SEITON)1)Sort(SEIRI) 2)Set In Order (SEITON)

3)Shine(SEISO)3)Shine(SEISO) 4)Standardize(SEIKETU) 4)Standardize(SEIKETU)

5) Sustain (SITSUKE)5) Sustain (SITSUKE)

6. Standard & example 6. Standard & example

6Kortek Let’s Win Customers

ContentsContents

All actions that do not occur added value in manufacture activity are waste.

The waste only raises a cost.

5S reduce a waste.

The goal of 5S are fundamental improvement of person, equipment, environment and enterprise.

The center of improvement is person, and the build up-awareness for all members is first.

7Kortek Let’s Win Customers

1. 5S Goal & 1. 5S Goal &

DefinitionDefinition

8

Efficient work-placeEfficient work-place Target achievementTarget achievement

Follow Work standard

Improve Workmethod

Think idea forWaste removal

Think idea for Waste searching

Improve Equipment availability

Analyze & record Work information

Make Clean

workplace

Create Lively

atmosphere




9

The type of waste in the field (The 7 waste of The type of waste in the field (The 7 waste of Toyota)Toyota)

1. Over-production Waste 2. Waiting Waste

3. Transporting Waste

3. Processing Waste

6. Motion Waste 7. Defects Waste

5. Inventory Waste




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What is 5S ?

Sort /Sorting (SEIRI) : Distinguish necessary and unnecessary item

→ Remove unnecessary and non-urgency item

Set In Order /Systematic Arrangement(SEITON) : Be use at any time

within 30 seconds

→ Every tool should have a place. Draw outlines on the wall or floor for easy recognition

Shine /Cleanliness(SEISO) : Cleaning → Make anyone can find defect

Standardize/Maintenance (SEIKETU) : 5S activity standardization → Maintain

clean condition

Sustain /Self Discipline (SITSUKE) : Ongoing improvement

→ Be habitual for procedures




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The 12 obstacles of 5S activity

Obstacle 1 – 『 Too late to do now! 』

Obstacle 2 – 『 Top mgmt. can not do such things 』

Obstacle 3 – 『 It will be dirty soon 』

Obstacle 4 – 『 Even if we keep clean or arranged, quality or productivity

does not rise 』

Obstacle 5 – 『 It is an uninteresting work 』

Obstacle 6 – 『 It have done already 』

Obstacle 7 – 『 Because I’m not uncomfortable, I’m okay 』

Obstacle 8 – 『 Such thing have done some years ago already 』

Obstacle 9 – 『 5S activities are issue of workplace 』

Obstacle 10 – 『 Because I’m busy, I have no time to do such things 』

Obstacle 11 – 『 I hate your order 』

Obstacle 12 – 『 Because profit remains, it is okay 』


2. 5S Obstacle2. 5S Obstacle

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The 7 major points to fixate 5S activity Point 1 – Top mgmt. is the responsible person

Point 2 – Announce officially → Nonofficial 5S activities are not spread.

Point 3 – Execution by all member → Everybody must participate.

Point 4 – Be clear purpose

Point 5 – Execute patiently → Do not feel annoyed and do sincerely

Point 6 – Top mgmt. checks the 5S activity directly.

Point 7 – 5S activities are the stepping-stone of company survival. → There is no improvement that do not go through 5S

activity.


3. Fixation Point3. Fixation Point

13

5S is the positive attitude of Yes!

1. Throw away a fixed idea

2. Think about becoming method

3. Analyze the actual condition instead of excuse

4. Wrong thing repairs immediately

5. Improvement which does not need money executes first.

6. Make do when urgent

7. The improvement is infinite

8. Ten people's wisdom than knowledge of one person

9. Pursue a fundamental cause and repeat “why” 5 times

10. Don't pursue perfection. Just try!

The motive power of 5S is the spirit which changes negative

mind into positive attitude


3. Fixation Point3. Fixation Point

14

Sort

Shine

Set In

Order

Standardiz

e

[ Method ]

Sustain

[ Goal ]


4. Expectation effect(Out put)4. Expectation effect(Out put)

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5S Effect Effect 1 – 『 Waste ZERO 』 : Cost saving and efficiency

improvement * Remove wasted motion for searching, transporting etc. * Reduce wasted space. * Overstocking is avoided. (Warehouse, shelf, cabinet etc.)

Effect 2 – 『 Accident ZERO 』 : Safety improvement * Cleaned machine and equipment can be notified hazardous

factor

* The storage place of the material comes to be clear

* Prevent collapse of products.

Effect 3 – 『 Breakdown ZERO 』 : Maintenance improvement * The garbage, dirtiness, dust shorten life of equipment

remarkably. * Prevent oil leakage and deal with a problem in advance.



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Effect 4 – 『 Defect ZERO 』 : Quality improvement * It is difficult to find failure in dirty workplace. * Can use the right parts in the right place.(3R) * Right storage of inspection & measuring instrument is critical.

Effect 5 – 『 Change over ZERO 』 : Be Multi products, productivity improvement

* Reduce wasted time looking for parts or tools. * The clean workplace improves a efficiency. * Arrangement of measuring tool can do preliminary preparations. Effect 6 – 『 Delay ZERO 』 : On-time Delivery Effect 7 - 『 Dissatisfaction ZERO 』 : Enterprise development * The trust becomes larger little by little. * The customer is satisfied.



Remove all items from the workplace that are not needed for current operations. Leave only the bare essentials.

KEY POINT : Removal

Method - Targets : excess inventory, obsolete items, quality defects, unneeded tools/equipment - Use red tags, if necessary - Take before and after pictures

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1) Sort /1) Sort /Sorting Sorting (SEIRI)(SEIRI)


5. Details5. Details

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Arrange needed items so that they are easy to find, use and put away.

KEY POINT : Everybody find easily

Method - Decide on appropriate locations - Consider how to store tools and jigs - Consider principles of motion waste - Visual controls

2) Set In Order /2) Set In Order /Systematic Arrangement Systematic Arrangement (SEITON)(SEITON)



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Sweeping, wiping-off equipment, painting and assuring

everything stays clean.

KEY POINT : Check

Method - Decide cleaning objects - Decide person in charge for cleaning. - Decide cleaning method - Decide cleaning tool

3) Shine 3) Shine //CleanlinessCleanliness(SEISO)(SEISO)



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Under the cleaning without dirt and garbage Keep the condition clean

KEY POINT : Identify the normal and abnormal condition easily

Method - Measuring tools are ready to use ? - Do every morning clean ? - Do arrange to end after work

4) Standardize /4) Standardize /MaintenanceMaintenance (SEIKETU)(SEIKETU)



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Keep the procedure or role practice without realizing it.

KEY POINT : Mindset to follow the procedure is basic.

Method - Use/develop Check Sheet - Perform patrol check - Encourage training/participation - Offer rewards and recognition

5) Sustain /5) Sustain /Self Discipline Self Discipline (SITSUKE)(SITSUKE)



23Dot line30

Yellow

Moving path indication of gate9

Circle50 pieYello

wChair position [each leg]8

100RedLoading line [Defect]7

100Yello

wLoading line [Inspection waiting]6

Solid line using right

angle

100BlueLoading line [inspection completion]5

" ㄱ“ Form30Yello

w work table, humidifier, garbage can, desk,

other location mark4

Avoid right angle

100Yello

wBoundary line (corner)3

Dot line100Yello

w

Boundary line (entrance) The line where the hand car, cart goes in

and out indicates a dot line [place where a person goes in and out indicates a solid

line]

2

Solid line100Yello

wBoundary line (passage)1

ExampleFormWidthColorName　100mm

150mm 150mm 150mm

50mm

100mm

100mm

Diameter 50mm

50mm 50mm 50mm

50mm

100mm

100mm

100mm

■ Boundary line standard


8. Standard & 8. Standard &

exampleexample

24

■ Work in process (WIP) storage

Item Purpose

Purpose

Subject

Standard

- In order to distinguish easily.

- WIP- Various TEST products etc.

- Horizontal writing is principle.- Indicate the type of products- Use the yellow writing on yellow Line- The distance of products line keeps away over 10mm.- Line width : 100mm- The distance between Pallets : 50mm.

Diagrammati

c



exampleexample

25

■ Transportation machinery mark

Item Purpose

Purpose

Subject

Standard

-Assign the storage area and responsibility in order to control repair, loss etc. easily.

- Cart, forklift truck, electromotive etc.

- Place left side, top area of transportation- If sticking is hard, place it seeing well - The place where the attachment is difficult fastens with string.- Put the line on floor with yellow line 50mm

Diagramma

tic Kortek Let’s Win Customers


exampleexample

26

■ Forklift truck storage method

Item Purpose

Purpose

Subject

Standard

- In order to do right position control

- forklift truck, electromotive etc.

- Separate Line and the outer wall of products does with 50mm.- Line marking does with a solid line.- Line color does with the yellow.- The right location mark width does with 50 mm.- Attach the name of designation place.

Diagramma

tic



exampleexample

27

■ Tool mark method

Item Purpose

Purpose

Subject

Standard

- In order to use easily.

- Tools etc.

- Indicate the line same as tool shape. And easy to hold the tool. - Place the tool information just above the tool and put the nameplate of user on the right side of tool box. - Nameplate of user indicates the destination of the tools in order to find easily.- The frequent using tool moves with SET units.

Diagrammati

c



exampleexample

28

A Max quantity mark

Min quantity mark

Item mark

Place mark

Location No.

<Parts signboard> <Parts RACK signboard>< Auxiliary equipment signboard>

■ Control example



exampleexample

29

<Example 1> < Example 2>

■ Direction mark

WallWorkplace

<Rotator direction mark> <Pipe fluidity direction mark> <Passage direction mark>

■ Tool arrangement



exampleexample

30

<Equipment cleaning, painting>

< Safety mark(Tiger mark)>

<Work area painting>

■ Cleaning example



exampleexample

WHAT U HAVE COME ACROSSWHAT U HAVE COME ACROSS AT THE END OF THIS TRAINNING. AT THE END OF THIS TRAINNING.

Followings can be possible from the 5S

1. NEAT & CLEAN WORKPLACE

2. SMOOTH WORKING

3. NO OBSTRUCTION

4. SAFETY INCREASES

5. PRODUCTIVITY IMPROVES


Cont.Cont.

6. QUALITY IMPROVES

7. WASTAGE DECREASE

8. MACHINE MAINTENANCE

9. VISUAL CONTROL SYSTEM

10. EMPLOYEES MOTIVATED

11. WORKSTATIONS BECOME SPACIOUS


Thank YouThank You


understanding 5S

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