SAFETY MEETING
5 S1
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Is a participative programme.
It is a very effective approach to improving our work,environment and total quality.
It becomes a base for continuous improvement in the organisation
5S---
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Summary
5s is a systematic approach to good housekeeping.
It is today gaining strong support in most industries, especially in Japan and there are increasing number of companies which are implementing 5s with greater involvement of people within the organisation.
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Why is it becoming popular among companies in Japan? Simply because:
1. Workplace becomes clean and better organised 2. Shopfloor and office operations become easier and
safer3. Results are visible to everyone insiders and outsiders4. Visible results enhance generation of more new
ideas5. People are automatically disciplined6. People become proud of a clean and organised
workplace7. Resultant good company image generates more
business etc.
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Some significant benefits observed at companies practising 5s include:
1. Happier employees with high morale.2. Greater people involvement. 3. Low employee turnover.4. Increased number of suggestions.5. Better use of floor space.6. Less work-in-progress and inventories.7. Better flow of work.8. Low machine breakdown rates.9. Low accident rates.10. High yield of materials.11. High product quality.
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The assumption why 5S is becoming so popular in Japan in recent years and in other countries today is that it emphasizes a people-oriented and also practice-oriented approach.
5S expects everyone-indeed everyone-to participate in it.
It is based on the belief that every individual can contribute to improving his/her workplace where he/she spends one-third of his/her life.
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What is 5S? The concept of good housekeeping has been with the
Japanese for a very long time.At home and in school ,children are disciplined to adhere to good housekeeping practices.However, it was only in the early 1980s that good houskepping became a pertinent issue in Japanese industries as companies realised its powerful contribution to productivity and quality improvement.
The basis for good housekeeping in Japanese companies is a concept popularly known as 5S.This stands for the five good housekeeping concepts in Japanese.
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Why a “5-S”movement1. Human beings feel good if work place is clean and well
organised.2. Helps in reducing time a. For searching things b. For handling 3. Helps in reducing a. Waste, inconsistencies & strain b. Unnecessary items & reserve stock c. Space requirement d. Machine downtime e. Rejection / Rework f. Number of accidents Helps people a. In seeing things more clearly b. In changing mindsets-develop a proactive attitude
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Meaning of “5S” 1. Segregation (SEIRI)
2. Arrangement (SEITON)
3. Cleaning (SEISO)
4. Maintenance of standards (SEIKETSU)
5. Discipline (SHITSUKE)
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What is 5S??5S Original Japanese Meaning in English
1S SEIRI Sort out unnecessary items in the workplace and discard them
2S SEITON Arrange necessary items in good order so that they can be easily picked for useA place for everythingEverything in its place
3S SEISO Clean your workplace thoroughly so that there is no dust on floors,machines and equipments
4S SEIKETSU Maintain high standards of workplace at all times
5S SHITSUKE Train people to follow good housekeeping discipline automatically
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Segregation ---SEIRI It helps to segregate necessary and unnecessary items
and eliminate unnecessary items. It essentially means organising / putting things in order.
ACTIVITIES1. Go through what you have2. Segregate/identify what you need3. Categorise needed/not needed items4. Discard What Is Unnecessary
INDICATOR OF SUCCESS1. Decrease in unnecessary items and reserve stock2. Percentage of area / space saved
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Arrangement --- SEITON This step essentially means arranging items efficiently,for
easy accessibility and using them in best order
ACTIVITIES
1. Set things in order by creating a place for everything.
2. Put everything in its place
3. Keep accessibility as easy as possible.
4. Use the principle of wide range and shallow depth for storage.
INDICATOR OF SUCCESS
1. Time saved in searching
2. Time saved in handling material
How to promote good order
Putting in order
Things needed Things not needed
Things usedConstantly
Things used occasionally
Seldom usedBut still needed
Place as closeas possible
Place as closeas possible
Place a littlefurther
Enclose in a sepearateDesignated
Place
Potentially usefull
No potentialuse
Consider where usefull and move
to designated place
Disposal aftercareful analysis
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Cleaning ---SEISO
This step eliminates dirt, dust and other foreign matter to make workplace clean and polished.
ACTIVITIES
1. Clean equipment, tools, furniture, records,etc.
2. Keep the workplace spotless
3. Sweeping, wiping, polishing, painting,etc.
INDICATOR OF SUCCESS
1. Reduction in machine downtime
2. Increased life of the machine parts
3. Reduction in number of accidents
4. Reduction in rejection / rework
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Maintenance to standards ---SEIKETSU
This Step is Combination of segregation (seiri), arrangement (seiton) and cleaning (seiso). As as,an on-going programme to maintain a clean and well – organised workplace.
Activities1. Create standards and initiate steps to maintain them2. Devise ways to a. Expose hidden problems b. Surface abnormalities3. Create visual control systemsIndicator of success1. Number of areas / covers made transparent2. Number of new problems exposed and solved
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What is an Abnormality ? An abnormality is any gap between actual performance
and the appropriate standard
EXAMPLES
Defective goods Scrap Equipment Failure Over Production Lateness Waiting
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What is the visual control ? A visual control communicates required important
information to people who need it.
It grabs one or more of our senses in order to : Alert us to an abnormality Help us monitor quickly Promote adherance and prevention Enable successful self management
Visual controls Reduce errors / waste by making problems visible Identify gap between standard and actual performance Help in early identification of problems Reduce supervision
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Visual control system A visual control system (VCS) is a series of visual
and other sensory devices integrated in order to achieve a particular outcome,ensure conformance and prevent waste
Example
1. Illustration of correct manual operation
2. Part containers colour coded to match the parts
3. Red colour light above the line that goes on when help is needed
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Important Points for preparation of visual controls
1. Easy to see from distance
2. Easy to understand
3. Ensure correct location/ placement
4. Use colours for brightness/contrast
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Important areas of visual displays1. Instructions to people to avoid “OPERATION ERRORS”
2. Danger alerts/cautions
3. Direction/locations
4. Equipment Designations
5. Planned programmes
6. Preventive maintenance/Calibration displays
7. Appeals
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Discipline --- SHITSUKE This step is to ensure that everyone sticks to the
rules scrupulously and makes it a habit
ACTIVITIES Create general awareness about 4S Training to everyone Share success to get more enthusiasm
INDICATORS OF SUCCESS High employee morale Involvement of people in the movement
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The Elements of “5S”
O R G A N I S I N G / P U T T I N Gt h i n g s i n o r d e r s o r t i n g
1 . R e m o v i n g w h a t i s n o t n e e d e d2 . K e e p i n g w h a t i s n e e d e d
C L E A N I N GK e e p i n g t h i n g s c l e a n a n d
p o l i s h e d , N o t r a s h o r d i r ta n y w h e r e i n t h e w o r k p l a c e
A R R A N G E M E N TP l a c i n g t h i n g s s o t h a t p e o p l e
c a n e a s i l y r e a c h w h a t t h e yn e e d w h w n e v e r t h e y n e e d i t
M A I N T . O F S T A N D A R D SM a i n t i n g c l e a n l i n e s s a f t e r
o r g a n i s a t i o n , a r r a n g e m e n ta n d c l e a n i n g a n d e s t a b l i s h i n g
D I S C I P L I N EA d h e r a n c e t o s t a n d a r d s d e v e l o p e d
t h r o u g h 4 S s t e p s b y a l l e m p l o y e e s o f t h ew o r k p l a c e
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5 Levels of housekeepingLEVELS1. Horizontal surfaces/floor full of unwanted material.
2. Vertical surfaces / areas near walls having clutter.
3. Horizontal ,vertical surfaces clean and have no unwanted items.However,storage areas, record rooms disorganised.
4. Storage areas ,machines,offices are clean.All materials ,furtinuture,documents properly organised,labelled and numbered.
5. Factory/office is immaculate at all times.
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Level 1 of HousekeepingWork area is in level 1 of housekeeping if, Cigarette butts/Gutkha pouches Scraps of paper Tools (Used or Unused) Packing and clamping materials Support structures Left -over raw material Obsolete documents Bulky files Unused equipment,machine etc
are scattered around all over the workplace.
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Corrective action for level 1 Look at all horizontal surfaces Examine the entire work floor.Eliminate all garbage and non- essential items on floor,shelves,tabletops etc Remove unnecessary papers from files Discard old files,stationery etc Make a definite place for all tools/documents,files and parts
that are lying on the floor tabletops
HINTS FOR IMPROVEMENT
Do not put anything directly on the floor As much as possible, throw/dispose off things that have no
clear foreseeable use.
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Level 2 of housekeeping Work area is in level 2 of housekeeping if there is no litter or
unused material on the floor/horizontal surface, but
Clutter is found by the walls
The passage ways are not clear
Unused items,documents,furniture etc are leaning against the walls or columns
Unused tools and equipment ,paper left beneath or beside the equipment
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Corrective action for level 2 Look at vertical surfaces
Examine walls and columns
Eliminate all garbage and non- essential items leaning against the walls/columns
Paint all walls and columns that can be reached by hand
Hint for improvement
Divide responsibilities (For area and walls)
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Level 3 of housekeeping
Work area is in level 3 of housekeeping if the walkways are clear and the factory/office is clean,but the tools,materials,papers and files are still disorganised in the storage areas,record rooms,drawers,filing racks etc.
Tools ,parts,clamps are all mixed together Gloves,shoes etc are thrown in with tools in the toolbox Drawers,shelves are disorganised All tools are in locked storage units Drawers,shelves are locked and keys are missing Unused and worthless items found inside closed cabinets
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Corrective action for level 3 Look inside the shelves and sort the papers, material
,parts and tools
Get rid of locked cabinets
Make separate storages for tools,parts,clamps, documents etc.
Make the above area distinct and clear
HINT FOR IMPROVEMENT
Remove the back and sides of all the storage cabinets
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Level 4 of housekeeping At level 4,the work area will have,
Machines,equipment,furnitures spotlessly clean
Storage areas clearly marked and distinguished
Scrap material found in its designated scrap bin
Items placed in shelves are properly labelled/ tagged
Storage areas show many parallel lines and right angles for grid alignment
Tools/files are colour coded and numbered
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Further improvement at Level 4 Clean ,straighten and organise automatically Storage system designed for “First In First Out”
philosophy Develop other visual controls
Hints for improvement Scrap and chips should fall directly into waste
containers/dust bins Make a model line with super market type display
of parts and tools Well defined scrap & waste collection & disposal
system
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Level 5 of Housekeeping
At level 5,the work place is immaculate at all times.It witnesses,
Constant and continual cleaning by all employees Origins of rubbish are removed so that dirt,clutter and
garbage are eliminated at source Tools,items and materials can be found at a glance Inventory levels can be found visually Production runs smoothly High product quality achieved
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Workplace rating In third rate workplace ,people leave trash and
no one stops to pick it up
In second rate workplace, people leave trash but others pick it up
In first rate workplace, no one leaves trash,but people would pick it up, if they saw it.
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What does 5(S) require? Consciousness revolution through,1. Perseverance,determination2. Training3. Constant efforts
Abilities1. To see / judge what is important2. Attention to details
Continuous implementation through Total participation by all employees
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8 crucial points for successful implementation of 5S
PARTICIPATION BY ALL PEOPLE 5S programme should be participated by all People in the
organisation. One day should be set aside for the launching of the
programme. 6 objectives or why’s of 5S programme should be
understood by all people in the organisation,1. A clean workplace is high in PRODUCTIVITY2. A clean workplace has high QUALITY3. A clean workplace keeps COST down4. A clean workplace ensures DELIVERY on time5. A clean workplace is SAFE for people to work6. A clean workplace is high in MORALE
The programme would be more effective when it is included in the small group activities like Quality Circles.
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The programme requires top management commitment
The programme should be practised during working hours as an authorized programme,but should not be treated as casual or extra activity during overtime or off duty hours.
Everyone should be officially informed of the significance of the programme.
The CEO should personally make an official announcement of the launching of the programme at an information sharing meeting attended by all people of the organisation.
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The CEO should take leadership of the programme
The CEO himself should be keen and committed and have a vested interest in the programme.
The CEO should not delegate the leadership to other people.
The CEO should exercise his leadership in 5S steering committee.
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The programme should be supported by all
Such doubts “Why are the disposal notices posted for SEIRI ? ” “ Why is 5S improvement for shopfloor improvement?” should be eliminated.
Each committee member should keep everyone informed of the current progress of 5S implementation on a departmental level.
Each committee member should encourage and guide his people for involvement in 5S implementation activities.
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5S Programme should be self- sustaining Banners,slogans,posters and newsletters should be fully
utilized to draw attention of everyone to this programme An easy handbook or a pamphlet illustrating “Why 5S”
“What is 5S” and “How to implement 5S” should be printed and distributed to everyone.
Periodic 5S implementation review should be conducted by CEO or an external expert for comments and updating the status quo.
Basic in-house training and introduction to model companies that have successfully implemented 5S practices would not only provide the necessary skills but also give an insight into how other companies implement 5S.
After the company has attained a certain level of implementation,participation in “Inter- company 5S competition” should provide greater motivation for further improvement.
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The CEO should make a periodic factory tour in person
The CEO should tour the factory from time to time and point out strengths and weaknesses of 5S implementation in each workplace.
The CEO should advise 5S steering committee to take corrective action in the areas identified.
The CEO should check the progress of the implementation.
The CEO should give recognition to improved or better practice.
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The programme should generate sufficient impact at the initial stage
Slow implementation of decisions by the 5S steering committee should be avoided.
“Disposal notice” approach for SEIRI which is the first step to 5S should especially be implemented company-wide for a specified time before proceeding to SEITON which is the second step for 5S.
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Implementation of 5S should go hand –in –hand with other Kaizen programme
5S especially at SEITON requires certain Kaizen principles and skills which can be acquired via external or well organised in-house training programmes.
SEITON requires logical problem-solving approaches.In this sense,it can well be a good theme for Quality Circle activities.
SEITON also requires creative ideas from everyone.Therefore,it can be tied in with and employee suggestion scheme.
Successful implementation of 5S will,by itself,bring about various tangible results.It is also a necessary step for a company to go through before implementing advanced management technologies such as TQC,JIT and TPM because 5S buildsup a solid foundation for SHITSUKE.
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Tangible results expected from 5S practice
From People Employees will be disciplined to be more aware of untidy
workplace and motivated to improve the level of cleanliness.
Greater team spirit and co-operation can be built up through involvement of all within an organisation.
Employees will be disciplined to follow safer and better ways of work,resulting in lesser risks to accidents.
Employees would be more conscious of improvement which leads to greater efficiency and effectiveness.
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From Machines and Tools
Machine troubles can be detected at an earlier stage to prevent a major breakdown, when machines are cleaned daily by people operating them.
Daily cleaning of measuring instruments will ensure accuracy and reliability.
Life of machines and tools can be extended significantly when they are handled with care and placed in the designated locations.
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From materials and Work –in -Progress
Flow of materials and work-in-progress will become smoother.
Floor space will become organised and possible areas for improvement can be easily identified by quick observation.
Inventory of materials and work-in-progress will become clearly visible and easily handled.
Material yield ratios can be improved
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From Products and Customers
Clean workplace will ensure that final products will be free from dust.
Sales people will be eager to show customers the plant as a marketing tool.
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Housekeeping to Happiness Housekeeping means Orderliness
Orderliness leads to Cleanliness
Cleanliness leads to Quality
Quality leads to Productivity
Productivity leads to Prosperity
Prosperity means Happiness
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