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Best Performing Consulting Organizationby5-S MethodologyAdding Value In Totality !!

Introduction to 5S5S is an approach originally developed in Japan for better house keeping. Now it is been utilized for keeping better work place.It includes 5 steps which are to be followed sequentially.Following Japanese terms collectively are as called 5S1S - Seiri or Sort 2S - Seiton or Set In Order3S - Seiso or Shiny Clean up 4S - Seiketsu or Standardize 5S - Shitsuke or Sustain By Implementing 5S one will get to know how cleanliness, orderliness, safety practises and better work environment results in increased free space, higher yield and transparency in work.Requirements of 5STo implement 5S following are the requisitesConsciousness forStrong determinationTrainingConstant EffortsAbility toJudge what is importantAttention to detailsContinuous implementation through total employee participation and better communication

1st S Seiri or SortStep 1 : Tagging the followingNot needed at allNeeded But Not NowNeeded But Not HereNeeded But Not So Much QuantityStep 2 : Entry in Red tag Register Step 3 : Assign Red Tag area and dump the scrap

It aims at taking out unnecessary items and dumping it into garbage(i.e Red Tagging)

Tools

Step 1 Step 2 Step 3 Action during Seiri

Red tag anything that is not needed !In manufacturing departments that means checking stock, machines, equipment, particular locations such as shelves , etc.In clerical departments it includes documents, stationery and machines .However, you should never ever red tag people, even if you are sometimes tempted to!What do we attach red tags to ?

Key IndicatorsIndicators of successDecrease in unnecessary items and reserved stocksReduction in sq.ft area consumedChecklist Do you find items scattered in your workplace?Are the boxes ,papers and other items left in a disorganized manner?Are there equipment and tools on the floor ?Are all items sorted out and placed in designated spots?Are tools and stationary properly sorted and stored ?

Result from Seiri

Created free space

SEIRI - Removed Unwanted Items

Cash flow improved!2nd S Seiton or Set In OrderIt aims at arranging the necessary items in proper order so that they can be easily picked up for useSteps for SeitonSystematic Arrangement is a form of standardization3 Keys are the basic rules for StorageFixing PositionFixing QuantitySigns for Storage of Work-in Progress

Systematic Arrangement KEYWORD 3 POINTS 3 KEYS - Anybody - ImmediatelyCan seeCan take outCan returnWhere?.. Fix positionWhat? Fix itemsHow many? Fix quantity3 KEYSIt answers the question

What items are to be kept ,where and in how much quantity ?Rules for StorageSearch FreeCount FreeAir FreeClimb FreeBend FreeFirst In, First OutHeavy/ Tall Things On Bottom ShelvesFast Moving Materials Close To Point-of-use/ Point-of-issueAdequate LightingAdequate Ventilation

Street numbersAddress of bin:A32=Block A, Street 3, House 2House numbersBlock tablesFixing Position Limit the size of storage places and shelves.Clearly indicate minimum and maximum stock quantities : Maximum red Minimum Green A mark is better than numbers.Quantity should be clear at a glance , without the need for counting. Fixing QuantityUsage frequencyRules for deciding where

1. Every day - Within Prime Real Estate of User (exclusive use)2. Occasionally -Within the gemba (to be shared by people at the gemba)3. Seldom -Within the company/unit (to be shared by all in company)Avoid use of horizontal surfaces for hand tools and light material generally not applicable to direct material.Each piece of an item should be kept separately, as far as practicable.Introduce Kanban cards to facilitate re-ordering in stores.

Rules for deciding where:ToolsFor Eg. Colour coding for files/tools, tool organizer to organize tools, shelf colour/tagging etc.The purpose of 5S Seiton is to find a place for everything within your working area, everything should be located as close as possible to where it is needed and at a location that is both safe and easily reachedFollowing are few eg.

Examples

BeforeAfterSearch Time Elimination

Fan & Electrical SwitchesIdentified Shadow Boards

Only shadow .. Empty boardShadow board with tools

Pre fixed location

Identity at empty place You know who has taken the file

Operation Standards At Operators Eye Level

Seiton - Arrangement of Moulds

Marking Reference Materials with an Oblique Line Out of Order In-OrderSeiton for StoreMake your Store: Search free Air free Climb/Bend free Count free FIFO Warehouse is where material is dumped in any quantity. Store has Reserved Seats.

Seiton-Floor Markings for Standard WIP

Two-Bin SystemKanban cardWhen bin is empty, card is placed here, to be picked up periodically by PurchaseSeiton

Transparent containers litres marked; red= reorderDrip catcherOil Storage Systematic ArrangementSeitonSeiton- Floor marking guideline 1/2

Seiton- Floor marking guideline 2/2Painting StandardTYPECOLOR WIDTH(cms)NOTESDividing linesExits/EntrancesDoor openingsTraffic flow linesTiger patternYellowYellowYellowYellowBlack & Yellow8-108-108-108-108-10Solid linesBroken linesBroken linesArrowsStripesStorageSpace linesWork-in-progressWork tablesAshtrays, etc.Defective itemsWhiteWhiteWhiteWhite5535Solid linesCorner linesBroken linesSolid lines

Actions in SeitonSeitonSuccess IndicatorReduction in handling/searching timeChecklistAre passage ways and storage places clearly indicated?Are commonly used tools and stationery separated from those seldom used?Are containers and boxes stacked up properly?Are fire extinguishers and hydrants readily accessible?Are there grooves, cracks or bumps on the floor which hinder work or safety?

3rd S- Seiso or Shiny Clean up 1/2Clean your workplace so that there is no dust. In workplace, it becomes easy to trace leaks, cracks etc.This stage has two goals:Determine and gain agreement on the desired level of cleanlinessLearn how to make new routines so this will become standardized (in the Seiketsu stage)Several questions help this stage to be more than just "polish until it shines for inspection":How much cleanliness is required for safety, for ease of use, and to minimize equipment breakdown?How clean should the environment be for comfort and morale?

Seiso 2/2How will cleanliness improve product quality?While cleaning, do we notice maintenance issues that should be addressed?

SurroundingsEquipmentStorage Areas

Cleaning Targets FloorsWork areas Aisles Walls Pillars Ceilings Windows Rooms Electric Lights

Surroundings : What to Clean ? Are there any unnecessary items around you ?Are all files & folders immediately accessible ?Is cleaning done every morning ?Is clearing up done every day after work ?Maintaining A Spotless Workplace

The purpose of cleaning is to get rid of all dust and dirt and keep the workplace spotless.Do you clean your workplace every day?Decide what to clean.Decide who is in charge of each cleaning task. Decide on cleaning methods.Prepare cleaning tools and equipment.Implement cleaning.

Consolidating Daily Cleaning Procedures

Identifying abnormality during ShineAfter the cleaning is done, special care should be taken: 1. To reorganize problem areas 2. Fix equipment that may be leaking 3. Take steps necessary to ensure that the problem will not persist in the future.

Example of 3SFactory Surroundings

FACTORY ENTRANCESCRAP YARD

Front area and Scrap yard are comparableShine in heavy machines

Machine lifted above the floor easy to clean from 6 sides

Transparent SheetsDark to brightAppropriate light for workplace

5 mins. For 5 S.

SeitonIndicators of SuccessReduction in machine downtimeIncreased life of machine partsReduction in number of accidentsReduction in rejection/reworkChecklistAre the floor surfaces dirty ?Are machines and equipment dirty?Are wires and pipes dirty or stained?Are machine nozzles dirtied by lubricants and ink ?Are shades, light bulb and light reflectors dirty?4th S- Seiketsu or StandardizeThis phase draws on the notes from the Seiso stage A practical target is to have all workers take five minutes every day to tidy up after themselves including the time to complete and sign the checklistsBy dividing the work among all the employees:No-one has a huge burdenNo-one seems unproductiveMorale improves because everyone has a common purposeSupervisors should monitor compliance with Seiketsu. The checklists make this both important and achievable.What Is To Be Standardised Workstation layout, work area layouts. Work in Process (WIP). Sequence of work. Cycle time of work . Material and tools used. Machines and their process parameters. Quality parameters, methods of measurement, reaction plan and reporting method. What, Where, When, Who & How of work .Methodology to practice 4S

Preparation of S.O.P.( Standard Operating Procedure) for all the activities to be carried out to maintain 1S,2S, & 3S.Following areas shall be covered while preparing S.O.P. : Machine & Equipment maintenance.Manufacturing Processes maintenance.Work Place maintenance.Quality Standards and Procedures maintenance.

PDCA------>>SDCA

SeiketsuIndicators of SuccessNumber of areas/cover made transparentNumber of new problems exposed & solvedChecklist Is the standardization system company-wide ?Is the setting, revision , and abolition of standards encouraged ?Have official procedures been laid down for setting, revising, and abolishing standards ?Is accumulation of technology promoted ?Are standards being utilized ?Are standards up to-date and capable of being put into practice

5th S- Shitsuke or Sustain 1/2Clear deliverables & communication.Score KeepingContinuous improvement with cyclic mini-5S events.Tools:Training and Awareness of 5SDedicated 5S teamClear 5S Map and Responsibilities/Ownership.

Shitsuke 2/2

051015202 SSYSTEMATICARRANGEMENT1 S SORTING 3 S SPIC & SPAN4 S STANDARDIZATION5 S SELF DISCIPLINESectionDateMarksMonthGraph100806040205'S' Radar Chart STEP II 5S ChecklistSectionClassCheckerDate5SChecking ItemMarks 1. The Red Tag Tactic has been implemented.01234 /20 2. There are no unnecessary items at the workplace.01234 3. Maximum quantity levels are clear at a glance.01234 4. Quantity control is in effect for storage.01234 5. There are no extra quantities in the work area.01234 6. Office organization and clearing up have been implemented.01234 /20 7. Organization of jigs & tools by shape is in effect.01234 8. Organization of materials, oil, jigs & tools by color is in effect.01234 9. Parts for mass production are stored by product.0123410. Lines for jigs & tools have been created.0123411. Cleaning has become habitual.01234 /2012. Cleaning includes checking.0123413. Responsibility for each cleaning area has been determined.0123414. A checklist for cleaning & checking is being used.0123415. The whole workplace is sparkling clean.01234Unsatis-factoryNot too badAverageBetter thanAverageSufficientTotalSORTINGSYSTEMATICARRANGEMENTSPIC & SPANContdChecklist 1/2

STEP II 5S ChecklistSectionClassCheckerDate5SChecking ItemMarks16. There are standards for the elimination of unnecessary items.01234 /2017. Immediate action is taken if storage becomes disorderly.0123418. Cleaning is initiated whenever if dirt is discovered.0123419. The whole factory is clean inside & out.0123420. The first three steps of 5S have become habitual.0123421. The boss is very active with regard to 5S.01234/2022. All the workers are enthusiastic about 5S.0123423. The boss gives stern criticism for disorder at the workplace.0123424. Subordinates respond positively when criticized.0123425. Everything is based on 4W1H.01234 Total marksUnsatis-factoryNot too badAverageBetter thanAverageSufficientTotalSTANDARDIZATIONSELF DISCIPLINEChecklist 2/2So, what were the results of the 5S Checklist?If your total mark was below 30, its a good idea to go back Gemba1.0 -30Unsatisfactory Back to Gemba2.31-50Below AverageReview particularly those items with low scores, and redo the test 3.51-70Average Needs reinforcement of weak points4.71-90Above AverageBut aim even higher 5.91-100Excellent Keep up the good work !Checkpoint : Total marksThe factory where 5S has taken rootShitsukeIndicators of successHigh Employee moraleInvolvement of people in the movementChecklist Are regular 5S checks conducted?Do people clean without reminder?Do people follow rules & instructions?Do people wear their uniforms & safety gear properly?Do people assemble on time?

How to implement 5S Define ScopeWhere?-Identify where exactly boundary starts and ends?Who?-Define the 5S team and participants with the visuals.

How to implement 5S 2/3Define ScopeWhat?-Define the 5S job responsibility with required resources?When?-Settle down a plan for 5S activities with target dates and checklist for routine

How to implement 5S 3/3Collect Baseline DataUse pictures and dataUse pictures of Before and After (Inside outside,Above-under)

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