1. Managing Quality & Productivity

2. What is Work place?Workplace is where one worksWhere there is an outputWhere there is creative activity!Where value is being addedIt is where one spends the largest part of his living time. 3. Importance ofWork place in ones lifeOn an average one spends his whole day as below:25-30% Time sleeping5-15% Traveling15-25% with family5-10% having food35-40% in WORKPLACEThat is , about 50% of our wakeful time, we spend in our workplace 4. How is your work place?Lovable or Likeable Threatening or Inviting?Can we make our work place excellent, so thatlife is fulfilling and enjoyable. And we & ourorganization become excellent? 5. Your work place should be an enabler!Because good workplace is what enables usto-Provide for our familiesEarn our salariesGive good educationto our childrenANDImprove our 6. Why is your organizations health important to you?A healthy organization showersprosperity on its employees.How does good work place help your organization?MY WORK PLACE HELPS MY ORGANIZAIONTO Create products Manufacture Products Reach them to customers Execute growth plans& Create value for customers Our Organization My co-employees and All other stake holdersIf it is not in excellent condition, ourorganization would also not be.If it is good it would ADD more value to myorganization.Workplace becomes good through 5sI dont have to wait formaterials, I can get any tool Ineed in seconds and I dontget tired through heat, sweatand poor ventilationHOW? 7. GOOD ENVIRONMENTBAD ENVIRONMENTThis enables me and myorganization to improveperformanceWhen: I organized my workplace well.The physical and psychological environment became better Atmosphere became serene Activities got STREAMLINED and Wastages were avoided.Just as your body andattire indicate yourpersonality, conditionsof your work placealso indicates yourpersonality. 8. Positive group engaged in 5sI consider my workplace asa symbol of myself and anextension of my personality.It is like the shirt I wear.I dont like to wear a dirtysmelling, bad quality shirt.It is below my dignity, sameabout my work placeBloodyHitlerBossWorkinghere is a bigheadacheA highly Negative, Argumentative, Stressful shop floor is unhealthy 9. For a goodPHYSICAL &PSYCHOLOGICALENVIRONMENT, weneed- Orderliness Good Organization CleanlinessNo wastage of time No wastage ofenergyNo wastage ofmaterialNo pinpricks likeheat, poorventilation, badlight, dust, dirt, etc.& alsoA GOOD CULTURE5Scannot beimplementedwithout properculture 10. What is 5s?The 5S System is a series of activitiesdesigned to improve workplaceorganization and standardization.Standardization in the workplacesimplifies everyday activities leadingto time-saving improvements.5s 11. Seiri - SortingSeiton - Systematic arrangementSeiso - Cleaning-Inspection while cleaningSeiketsu - StandardizationShitsuke - Self Discipline 12. 5S Principles Elimination of waste Every body is involved, Co-operative effort Attack root cause Human being is not infalliable 13. 5S Objectives Improve housekeeping Make every individual responsible for housekeeping Beautify by simple means Productivity improvement by saving time, space etc. 14. SEIRI = SortingMeaning Distinguish between necessary and unnecessaryitems and eliminate the unnecessary itemsActivity Establish a criteria for eliminating unwanted itemsEliminate unwanted items either by disposingthem or by relocating them.Success Area saved or percentage of space availableIndicator 15. SEIRI = SortingJapanese Meaning : The Japanese meaning ofSeiri is to straighten and contain.- Get rid of waste and put it in order according to rulesOTHER JAPANESE MEANINGS -farmland cultivation, Make an orderly system andstraighten15 16. Seiri = Sorting1. Item is not neededWhat is unnecessary2. Item is needed however quantity in stock is morethan what is needed for consumption in nearfuture3. Contingency PartsCritically decide the quantity of contingencyparts to be retained and criteria for such parts 17. OrganizationFrequency of use Storage Method*Things you have not usedin the past one yearThrow them out*Things you have used oncein the last 6-12 monthsStore at distance ORKeep in storeLOW*Things you have used onlyonce in the last 2-6 monthsStore it in central placein your zone*Things used more than oncea monthStore it in central placein your zoneAVERAGEHIGH *Things used once a week Store near the workplace*Things used daily or hourly Store near the workplace 18. Seiri = Sorting Identifying 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.. 19. Seiri = Sorting Identifying unnecessary2. Tools, Toolings, Measuring devices Old jigs, tools not in use are lying Modified tools, tooling for trial, are lying after trialWorn out items like bushes, liners, toggles etc. lying Broken tools, bits, etc. may be lying Measuring equipment not required for the operationbeing performed , is lying3. Contingency Parts Many times storage place for contingency parts becomea last refuge for broken parts, surplus items and thingsnobody is likely to useContd.. 20. Seiri = Sorting Identifying unnecessary4. Shelves and Lockers Shelves and lockers tends to collect things that nobodyever 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 piecesContd.. 21. Seiri = Sorting Identifying 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 22. Seiri = Sorting Improvement methods1. Flow Process Chart (Procedural Analysis)Drawing a process flow chart for the systemeg. How to make and use category wise grouping2. Operational AnalysisPreparing 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. 23. Seiri = Sorting Dealing with papersHow to reduce papers onyour table ?1. Make a single pile of papers2. Go through them and sort infollowing categoriesa) Immediate actionb) Low priorityc) Pendingd) Reading materiale) For information 24. Seiri = Sorting Dealing with papersHow to reduce papers onyour table ?4 D PrincipleDODELEGATEDELAYDUMP 25. SEITION = Systematic ArrangementMeaning To determine type of storage and layout thatwill ensure easy accessibility for everyone .Activity - Functional storage- Creating place for everything and puttingeverything in its placeSuccess - Time saved in searchingIndicator - Time saved in material handling 26. SEITION = Systematic ArrangementJapanese Meaning:Dictionary meaning of Seiton is to be correctlypreparedand to prepare correctly.In short these means :(a) arrange correctly in accordance with the correct method ofdoing activities and(b) make thorough preparations so that activities can be doneeven if they occur abruptly 27. SEITION = Systematic ArrangementThe main target areas for Seri-Seiton improvement are :Tool-setting and preparation operations, line balancing andprocess planning, parts supply to assembly line, peak timeproblems etc.Improvement MethodsKit Method / Assembly box method / Outside tool settingCassettisation / Parallel operations / Changes in assignmentmethod 28. Seiton = Systematic ArrangementHow to achieve Systematic Arrangement ? Decide where things belong Decide how things should be put away Obey the Put away rules 29. Seiton = 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 itemand location- Store material functionally- Prevent mistakes with coding by shapes & colourcontd.. 30. Seiton = 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 storethem separately, colour code them. Obey the rules- Put the things back to their location aftertheir use 31. Seiton = Systematic ArrangementUSE :1 ) Signboards2) Colour codes3) Outline markings4) Labels 32. Seiton = Systematic ArrangementFunctionalStorage 33. Seiton = Systematic Arrangement33UsageFrequency Store frequently used materialnear the workplace and lessfrequently at some distanceWeight &Shape of theMaterial Heavy material should be storedat lower levels/layersPlace directly on the materialhandling device for ease ofhandlingFunctional Storage 34. Seiton = Systematic ArrangementCategory Same category of material may bestored in one location.Eg. Allen Screws, Oil SealsOperationWise All items required for anoperation may be stored in onelocation.Eg. Allen key, spanner etc handtools required for setting m/cFunctional Storage 35. Seiton = 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 bemoved 36. Seiton = Systematic ArrangementWires and Ducts- Colour code-When there are multiple connections - bundle thewires, label them and make sure that they are instraight 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 beput away with one hand- Try to eliminate some hand tools by permanentlyattaching it to the bolt head 37. Seiton = Systematic Arrangement Blades, Dies, Other important consumables- Store them in the protected place- Maintain these things regularly by applying rustpreventive, 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 partduring transit, they do not get rusty and they arenot mislabeled 38. Seiton = 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 39. SEISO = CleaningMeaning Cleaning trash, filth, dust and other foreignmatter. Cleaning as a form ofInspectionActivity - Keep workplace spotlessly clean- Inspection while cleaning- Finding minor problems with cleaning inspectionSuccess - Reduction in machine down timeIndicator - Reduction in no. of accidents 40. SEISO = CleaningJapanese Meaning :Dictionary meaning to clean up andgetting rid of dirt and unclean itemsWhile cleaning potential defects such as abrasion,damage, loose parts, deformities, leaks temp.,vibration, abnormal sound etc. are revealed henceSeiso is Inspection 41. Seiso = Cleaning Here cleaning means more than just keepingthings clean. Cleaning should be viewed as aform of Visual Inspection Preventive measures should be taken to tackleproblems of dust, grim, burrs, leakage etc.Root cause of the problem should be identifiedand it should be eliminated 42. Seiso = CleaningVarious Minor Defects= Trash = Dirt =Knocking= Loose parts = Leaks =Scattering=Skips =Curvature =Abrasion=Rust =Scratches=Eccentricity=Lurching =Abnormal =VibrationMovements=Abnormal =Heat =AbnormalSounds smells=Faded colour =Hisses 43. Seiso = Cleaning5 Minutes Every day for cleaning Devote 5 minutes everyday for cleaning yourwork area Participation of everyone is required Attack hard to clean places regularly 44. Seiso = CleaningCleaning-Inspection points for mostequipmentCleaning 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. 45. Seiso = CleaningCleaning-Inspection points for mostequipmentTightening Loose bolts, welding detachment,loose parts, vibration or bumpingnoise, frictionHeat Oil tanks, motors, heater, axles, controlpanels, washing/ cleaning water,bearing, wiring etc. 46. Seiso = CleaningCleaning-Inspection points for mostequipmentBreakage,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. 47. Seiso = CleaningFunction wise Cleaning check list ofequipmentPneumaticsHydraulicsCompressed Air lines, air valves,connections, meters, filters,reservoirs etc.Hydraulic oil tank, oil valves,filters, pumps, hoses, gauges,cylinders etc. 48. Seiso = CleaningFunction wise Cleaning check list ofequipmentMech &Power TrainElectricalMotor fan, fan belt, couplings,Joints, pulleys, chains, pumpbearings etc.Control panel, lamps, light, switch,sensors, wiring, ducts, fuses etc. 49. Seiso = CleaningFunction wise Cleaning check list ofequipmentToolingsEquipmentSpecificTools, fixtures, gauges, dies,measuring instruments, etc.Furnaces, rollers, chutes,CNC machines, etc. 50. SEIKETSU = StandardizationMeaning Setting up standards / Norms for a neat,clean, workplace and details of how tomaintain the norm (Procedure)Activity - Innovative visual management- Colour coding- Early detection of problem and early actionSuccess Increase in 5S indicatorIndicator 51. SEIKETSU = StandardizationJapanese Meaning :Dictionary meaningunsoiled things, purity and cleanlinessClean manners ,Clean cloths, clean politicianIt is the proof that 3 Ss are being faithfullycarried out. 52. SEIKETSU = StandardizationTools used for analysis :MTTRMTBFOEE 53. Seiketsu = Standardization Regularizing 5S activities so thatabnormalities are revealed Make it easy for everyone to identifythe state of normal or abnormalcondition For maintaining previous 3S, deployvisual management 54. Seiketsu = Standardization It has been estimated by scientificstudy that 60% of all human activitiesstarts with sight 5S is easy to do once. It is consistencythat is difficult. That is why VisualManagement is so important, so thateverybody will know that there issome problem. 55. Seiketsu = StandardizationWhat visual control communicates ?It grabs one or more of our senses inorder to Alert us to an abnormality Help us recover quickly Promote adherence and prevention Enable successful self management 56. Seiketsu = StandardizationSome methods for visual communication Color coding Use of Labels Danger alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators 57. Seiketsu = StandardizationSome methods for visual communicationLabels Precision management labels Inspection labels Temperature labels Responsibility labels 58. Seiketsu = StandardizationPoints to remember in making visual ccontrol tools1. Make them easy to see from distance2. Put the display on the things3. Everyone can tell what is right andwhat is wrong4. Anybody can follow them and makenecessary corrections easily5. Work place should look brighter &orderly 59. Seiketsu = StandardizationSome everyday visual managementexamples Traffic signal Zebra crossing In car - Petrol indicator- Speed indicator Direction arrows Electric danger sign etc. 60. Seiketsu = StandardizationSome visual communication signs 61. SHITSUKE = Self DisciplineMeaning Every one sticks to the rule and makes it ahabitActivity - Participation of everyone in developing goodhabits- Regular audits and aiming for higher levelSuccess High employee moraleIndicator Involvement of all people 62. SHITSUKE = Self DisciplineJapanese Meaning :Dictionary meaning islearning of the mannershaving manners, dressing neatly ORtraining children for good customs 63. SHITSUKE = Self DisciplineActivities :5S Committee5S Training5S Competition / evaluation5S MonthPosters , Literature etc.63 64. Shitsuke = Self DisciplineWe 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 65. Shitsuke = Self DisciplineDiscipline means making a steadyhabit of properly maintainingcorrect procedure.Time and effort involved inestablishing proper arrangementand orderliness will be in vain ifwe do not have discipline tomaintain it. 66. Shitsuke = Self Discipline PledgeIt shall be my constant effort tomaintain my workplace in goodorder by Assigning a place for everything& keeping everything in its place. Sorting out unwanted materialperiodically & discarding them. Keeping my work area neat &clean everyday