PRESENTATION ON5 S By-Prof.S.RajaniSchool of Management StudiesGVP College

CONTENTS Concept of 5 S Pillars of 5 S Implementation Summary

1950196019701980INDIAU.S.AJAPANQuality Improvements

WHAT IS 5S5S is an integrated Japanese concept for proper and orderly Work Place Management. It is an acronym derived from the first letter of five Japanese words, namely: SEIRI - Sorting out SEITON - Systematic Arrangement SEISO - Spic & Span SEIKETSU - Standardization SHITSUKE - Self-Discipline

This is applicable to all places Shop Floors, Offices, Homes etc.

THE FUNDAMENTAL TRUTHIf we cannot keep our workplaces - Clean - Orderly - Accident free nobody will believe we can produce quality goods 5 S is the silent informer of a companys attitude to quality.

WHY WE REQUIRE 5S

By adopting 5S, we can

Maintain clean & orderly work place. Create healthier corporate climate. Establish ambience for quality Optimize the space utilization Avoid time for searching Avoid tension and get more output. Prevent accidents

5S Principles Elimination of waste Every body is involved, Co- operative effort Attack root cause Human being is not infallible

SEIRI = SortingMeaningDistinguish between necessary and unnecessary items and eliminate the unnecessary items

ActivityEstablish a criteria for eliminating unwanted items Eliminate unwanted items either by disposing them or by relocating them.

SuccessArea saved or percentage of space availableIndicator Easy access to machines/work spots

SEIRI - SORTING OUTGo through what you have Classify all items into categories - necessary ; unnecessary Sort out and identify what is needed. Take out trash and rubbish from the work place immediately.Keep trash in its place.Identify unwanted items with a red tag. Dispose off what is not required. Items required regularly and in the near future to be kept in work place.

Places where unnecessary things can be found

Shelves and Lockers Shelves and lockers tends to collect things that nobody ever uses , like surplus material, broken items etc. Passages and Corners Dust & materials not required seem to gather in corner Besides Pillars and under the stairs These places tends to collect junk, used as spittoons.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 pieces

Contd-

Floor, Pits, Partitions Defective parts Protection caps, covers Packing material Hardware items , small items Even tools, tooling

Items dropped on the floor are never picked

Computer Hard Disk Many unwanted, outdated, temporary files pile up

WORK STATION EVALUATION PROCESSIs the item Required For production ?

Is the item Required In this Quantity ?Is the item Required at this Work station Location ?Create Appropriate Work Station Storage Location for Item Send item to Red Tag Area for Disposal Send Excess items To Red Tag Area for Disposal NONOYESYESYESDispose of Excess Items Next slideNO

RED TAG HOLDING AREA EVALUATION PROCESS Is the item required At a shop floor Storage location ?Is the Item required in this Quantity ?Create appropriate Storage location For Item outsideShop floor Create Appropriate Shop floor Storage location For Item Dispose of Excess Items NOYESYESFrom previousSlide NO

Use-Frequency Classification of things

FrequencyUsage of itemsMethod of handlingLOWThings you have not used in the past one yearThings you have used once in the last 6-12 months Dispose them

Store at distance OR Keep in storeAVERAGEThings you have used only once in the last 2-6 months

Things used more than once a monthStore it in central place

Store it in central place in your zoneHIGHThings used once a week

Things used daily or hourlyKeep near the workplace

Keep them in handy place

Dealing with papers

How to reduce papers on your table ?

Make a single pile of papers Go through them and sort in following categories

- Immediate action- Low priority- Pending- Reading material- For information

Dealing with papers

How to reduce papers on your table ?

4 D Principle

DODELEGATEDELAYDUMP

SEITION = Systematic ArrangementMeaning -To determine type of storage and layout that will ensure easy accessibility for everyone

Activity - Functional storage - Creating place for everything and putting everything in its place

Success- Time saved in searching Indicator - Time saved in material handling

How to achieve Systematic Arrangement

Decide where things belong

Decide how things should be arranged

Follow the System

Decide where things belong - Standardize Nomenclature - Determine an analytical method of storage Decide how things should be arranged - Name & specify locations to everything. Label both item and location. - Store material functionally. - Prevent mistakes with coding by shapes & colour contd..

Decide how things should be arranged - Follow first in first out rule - If two similar items are to be located, then store them separately, colour code them.

Follow the System - Put the things back to their location after their use

USE :

Signboards Colour codes Outline markings Labels

FunctionalStorage

SEITION = Systematic Arrangement

UsageFrequency

Weight &Shape of theMaterial

Store frequently used material near the workplace and less frequently at some distance Heavy material should be stored at lower levels/layers Place directly on the material handling device for ease of handling- Functional Storage -

Operation wise All items required for an operation may be stored in one location.Eg. Allen key, spanner etc hand tools required for setting m/c - Functional Storage -

Examples of systematic arrangementsOutlining 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 be moved Contd

Wires and Ducts - Colour code - When there are multiple connections - bundle the wires, label them and make sure that they are in straight 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 be put away with one hand - Try to eliminate some hand tools by permanently attaching it to the bolt head

SEISO = Spic and SpanMeaningCleaning trash, filth, dust and other foreign matter. Cleaning as a form of Inspection

Activity- Keep workplace spotlessly clean- Inspection while cleaning- Finding minor problems with cleaning inspection

Success - Increased efficiency of the machine Indicator - Reduction in no. of accidents - Develops skill of operator in autonomous maintenance

SEISO = Spic and SpanUndertake cleaning of the work place completely with the participation of everybody including top and senior managers.

Implement scheme in your own work area and make employees responsible for the designated areas.

Ensure that work places are cleaned daily before starting the days work and also at the time of closing the work.

Ensure personal cleanliness.

5 Minutes Every day for cleaning

Devote 5 minutes everyday for cleaning your work area

Participation of everyone is required

Attack hard to clean places regularly

Cleaning must be viewed as a form of visual inspection.

Root cause of the problem must be identified.

Minor defects can be identified-

Loose parts, rust, abnormal smells, heat, curvature,abnormal sounds,leaks,vibrations etc.

Common cleaning- inspection pointsCleaningGrime, clogging, dust balls, rust, leakage etc.

OilsNo oil, Low oil, leakage, filter clogging,dirty oil, dirty or bent oil lines, cloggeddrainage, oil spillage, worn & torn portsetc.

TighteningLoose bolts, welding detachment,loose parts, vibration or bumping noise, friction.

Contd-

Common cleaning- inspection pointsBreakage,CracksBreakage, cracks, dent on sliding parts,handle has come off, brokenswitches, wire joints come off, wiresare broken or crack, crack dial ofvarious pre. gauges, meters etc.

MechanicalMotor fan, fan belt, couplings,Joints, pulleys, chains, pump bearings etc.

ElectricalControl panel, lamps, light, switch,sensors, wiring, ducts, fuses etc.

SEIKETSU = StandardizationMeaning - Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm.

Activity - Innovative visual management - Colour coding - Early detection of problem and early action

Success - Increase in 5S indicator Indicator - Reduction in defects and breakdowns

SEIKETSU = StandardizationDecide a schedule specifying frequency and persons responsible for carrying out the above three Ss and ensure that it is done according to the schedule.

Eliminate the activities that make the work place dirty and disorganized.

Protect workers from dangerous and unsafe conditions.

Standardize operations and daily maintenance procedures.

Institute competition between various sections / departments for best organized and maintained workplace lay down criteria and determine the level of 5S activities.

Managers should take note of the status in their visits to the work place.

SHITSUKE = Self DisciplineMeaning - Every one sticks to the rule and makes it a habit

Activity - Participation of everyone in developing good habits - Regular audits and aiming for higher level

Success - High employee moraleIndicator - Involvement of all people

SHITSUKE = Self Discipline/Sustain Define rules & regulations. Set example by following the rules. Finish work in time. Do not be lax with self. Avoid indiscipline like:- Involvement in office politics and gossip.- Spreading , rumour & politicking

Common types of resistance to 5 S Whats so great about 5 S ? Why clean when it just gets dirty again? This will not boost output We already implemented 5 S We did 5 S years ago We are too busy for 5 S

Benefits of 5 S ImplementationTO YOU

Provides an opportunity to show your creativity in organizing your workplace and work.

Makes your work place more pleasant.

Makes your job more satisfying.

Makes it easier to communicate with everyone you work with.

Benefits of 5 S ImplementationTO YOUR COMPANY

Zero defects bring higher quality. Zero waste brings lower costs. Zero delays bring reliable deliveries. Zero injuries promote safety. Zero breakdowns bring better equipment availability. Zero complaints bring greater confidence and trust.

5S (Summary)

The SEnglish Meaning How to Implement?Advantages 1 SSorting out (SEIRI) Go through what you have.

Sort out and identify

Identify unwanted items.

Dispose off what is not required.

Decide on frequency of sorting. Work place becomes cleaner and spacious.

Easy access to things/items/parts.

Decluttering the work place.2 SSystematic arrangement (SEITON) Arranging in order

A place for everything & every useful thing in its place Minimizing search time

Improves work place utilization.

The SEnglish Meaning How to implement ? Advantages 3 SSpic & span (SEISO) Develop an attitude towards cleaning and inspecting.

Use required cleaning aids. Safe & pleasant working environment. Inspection made easy for problems. Taking corrective actions faster.4 S Standardization (SEIKETSU) Standardize working methodology (Procedures & Work Instructions) Reduction in defects / breakdowns. Helps in error free operation & process. Achieving higher Productivity & better Quality. 5 S Self-Discipline (SHITSUKE) Following the above four Ss consistently.

Forming good habits.

Training.

Be disciplined in all aspects of work. Promotes habit for complying with workplace rules and procedures. Results in continuous improvement. Develops team work. Improves safety and hygiene.