*Achieving Quality With 5 SPresented By:Harpreet Singh (18)Shweta Singh (28)A Place For Everything & Everything In Its Place

*5S is the foundation, the building blocks, for a Kaizen approach to incremental improvement. 5S focuses on the elimination of wastes( Muda) in the work environment: to include the office environment as well as the manufacturing environment.

In simplest terms , it is the cleaning up of all the wastes so that the work environment produces what it wants, at the time it is needed in the correct quantities.

What is 5S ?An essential step required for Waste Elimination

An integral step in KaizenA required element to achieve Lean-site Manufacturing.

Sorting OutSeiri

OrderlinessSeiton

ShineSeisoCleanupSeiketsu

StandardizeSeiketsu

Sustain/Perseverance Shitsuke

*5S was created in the Japanese manufacturing environment and literally stands for 5 Japanese words which begin with S:

Seiri, Seiton, Seison, Seiketsu, Shitsuke

When translated together mean a cleaning activity at a workplace.Aforementioned, 5S is an integral step towards Kaizen and Lean-site Manufacturing with the primary goal of being able to supply the customer ( internal,external) with the right product at the right time in the correct quantities.

Five S SeiriSeitonSeiketsuShitsukeSeisoSorting OutSystematic ArrangementStandardiseSelf DisciplineSpic-n-SpanS - 2S - 4S - 5S - 3S - 1

*Its Ibana

What is the Japanese language

Japanese- seiri- EnglishNotes-

Etsu evana- notes- debashis

Wallet exercise- what is the purpose, sorting- tell them about Seiri

Use words like

5sDrive Quality

*Logistics:Pani 2 service excellence

Design Notes: Builds automatically.

Content: 5S background - Based on Japanese words that begin with S, the 5S philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality, efficiency and safety.

PRICE FLEXIBILITY QUALITYDELIVERYSERVICETHE NEED FOR A "5S" STRATEGY

MUDA ELIMINATIONWASTEELIMINATIONLEADS TOCOSTOPTIMIZATION &MANAGEMENTEXCELLENCE

The first S focuses on eliminating unnecessary items from the workplace.Sort (Seiri)

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An effective visual method to identify these unneeded items is called red tagging. A red tag is placed on all items not required to complete your job. These items are then moved to a central holding area. This process is for evaluation of the red tag items. Occasionally used items are moved to a more organized storage location outside of the work area while unneeded items are discarded.Sort (Seiri)

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Sort (Seiri)

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Sorting frees up valuable floor space and eliminates such things as broken tools, obsolete jigs and fixtures, scrap and excess raw material. The Sort process also helps prevent the hoarder job mentality (I might need it).Sort (Seiri)

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Set in Order (Seiton)What do I need to do my job?Where should I locate this item?How many do I need?

The second S focuses on efficient and effective storage methods. You must ask yourself these questions:

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Strategies for effective Set In Order are:Set in Order (Seiton)Painting floorsOutlining work areas and locationsShadow boardsModular shelving and cabinets

A PLACE FOR EVERYTHING AND EVERTHING IN ITS PLACE

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Once the clutter and junk that has been clogging work areas have been eliminated and the necessary items have been identified and located, the next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary in order to sustain this improvement. Workers take pride in a clean and clutter-free work area and the Shine step will help create ownership in the equipment and facility. Shine (Seiso)

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Workers will also begin to notice changes in equipment and facility location such as air, oil and coolant leaks, repeat contamination and vibration, broken, fatigue, breakage, and misalignment. These changes, if left unattended, could lead to equipment failure and loss of production. Both add up to impact your companys bottom line.Shine (Seiso)

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Once the first three of the 5Ss have been implemented, emphasis should be on standardizing best practice in work area. Employees must be allowed to participate in the development and documentation of such standards. They are a valuable but often overlooked source of information regarding their work. Standardize (Seiketsu)

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Standardize (Seiketsu)Workplace Layout and DesignMaterials Handling AnalysisClear and Concise Work InstructionsWell Defined Work MethodsSafe (Ergonomic) Working PracticesCycle Time ReductionTrainingDocumentation

Standardize means establishing Best Manufacturing Practices, including:

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This is by far the most difficult S to implement and achieve.

Human nature is to resist change and more than a few organizations have found themselves with a dirty cluttered shop a few months following their attempt to implement 5S. The tendency is to return to the status quo and the comfort zone of the "old way" of doing things.

Sustain focuses on defining a new status quo and standard of work place organization.Sustain (Seiketsu)

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The 5S Philosophy

Once fully implemented, the 5S process can increase moral, create positive impressions on customers, and increase efficiency and organization. Not only will employees feel better about where they work, the effect on continuous improvement can lead to less waste, better quality and shorter lead times. Any of which will make your organization more profitable and competitive in the market place

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5S Performance Excellence Model

Orderliness (Seiton)Shine (Seiso)Self-Discipline (Seiketsu)Customer ExpectationsSorting Out (Seiri)Standardize (Shitsuke)Improved QualityImproved SafetyReduced costsConsistent DeliveriesImproved Product/ Service Options

*This model shows the inter-relationship of the 5S steps with the customers expectations of improved quality,improved safety, reduced nonconformance costs, improved product service options;thus, leading to a satisfied customer.Please note that the base of the pyramid is self-discipline-control. This step is key in maintaining the progress already achieved by the previous 4 Ss.

Also please note, that the deliverables are closely related to the deliverables of a Kaizen process.

Resistance to Implementing 5S

What are the reasons for resisting 5s implementation?Whats so great about sort and set in order? It will take too much time.Why clean when it just gets dirty again? Are sort, set in order, and shine really going to boost productivity?Why bother?We already implemented sort and set in order.Were too busy for 5s.We did 5s years ago.

*Discuss resistance-

BEFORE showing next slide,

Ask each person to answer/respond to/ or overcome their objection.

Show next slide

Potential benefits of 5S

What are some benefits of implementing 5s?Workers have an opportunity to provide creative ideas about how the workplace should be organized.Higher job satisfaction.Clear expectations.Reduced delays mean timely delivery of product.Reduced changeover time = higher productivity.Elimination of cost causing waste.Reduced defects and higher quality. Safer environment.Maintained machinery and equipment means reduced downtime. Win customer confidence and trust. Growth.

*Discuss how benefits overcome resistance

Potential benefits of 5S The potential benefits of 5S can be summarized by five English S or PQCDS.Five English S:Sales - Increase sales (market share). Savings - Save costs. Safety - Provide a safety working environment. Standardization - Standardize the operating procedure. Satisfaction - Employees and customers satisfaction

ContdPQCDS:

P - Increase productivity.Q - Improve product quality. C - Reduce manufacturing costs. D - Ensure on-time delivery. S - Provide a safety working environment

Implementation Procedure of 5SOrganize the program committee. (PLAN) Develop a plan for each S. (PLAN) Publicly announcement the start of the program. (DO) Provide training and education to employees. (DO) Select a day and everybody cleanups his/her own working area. (DO) Select a day and everybody organizes his/her own workplace. (DO) Evaluate the results of 5S. (CHECK) Self-Examination and Take corrected actions. (ACTION)

Case Studies

A Case of Timack Mfg. Ltd.A plywood and wooden frames Mfg. firm.Sales has reduced from 1.85m to 1.65m in two year.Management took help of a Manufacturing Institute from East Lancashire Business Link.They identified some key issues.

These issues were:The business is approximately at break even point there is a need to reduce cost and improve productivity, in order to start making a margin.The manufacturing lead time is excessive, compared with the value added process time.Stock levels are high.There is a seasonal trend in the business, with the busy period being March and April.The business is organized functionally, with separately managed areas.There is no measure of machine effectiveness.Production of samples for new products can be problematic.

Recommendation:Use value stream mapping to identify waste within the operation. This will enable aplan to be produced to reduce stock and lead time. Consider the need for annualised hours to cope with the seasonal variances indemand. (This may not be necessary if the lead time can be reduced). Consider a value stream management organisational structure. Consider the introduction of Overall Equipment Effectiveness (OEE). Consider the creation of new product samples as a separate value stream,perhaps with dedicated processes?

ContdA project team was formed, consisting of the two directors, the machine shop manager and assembly supervisor.Implementation of improvement took place over next four month.5S was implemented.

The photographs below show the improved workplace Organisation, as a result of the 5S activity

Before After

Results: 10% improvement in productivity (40.9k benefit) 5% improvement in delivery performance 33% reduction in stock (54.5k benefit) 33% reduction in lead time (3 weeks to 2 weeks) 2 jobs safeguarded 75k sales safeguarded 23k of value added safeguarded 10% reduction in sub standard supplies (1.2k benefit) 10% reduction in travel distances

Case Study Of Leisureline

Uncleaned Mixed Unordered Unarranged Untidy Ugly

Clean Sorted Ordered Arranged Neat Good Looking

How Does 5S Pay Off?

BEFORE 5S

AFTER 5S

Visits

1800

Visits

1800

Time Spent Each Visit

15 Min

Time Spent Each Visit

1 Min

Total Time for 600 Employees

450 Hrs.

Total Time for 600 Employees

30 Hrs

PRODUCTIVITY INCREASE (%)

93

Before sort After sort

Specific Objectives - SYSTEMATIZEOrganise layout of tools and equipmentDesignated locationsUse tapes and labels

Ensure everything is available

as it is needed and at the point of use

Specific Objectives - SYSTEMATIZEWorkplace Checkpoints:-Positions of aisles and storage places clearly marked?Tools classified and stored by frequency of use?Pallets stacked correctly?Safety equipment easily accessible?Floors in good condition?Lights / Reflectors clean?

Specific Objectives- SWEEP, SHINE, SCRUBCreate a spotless workplaceIdentify and eliminate causes of dirt and grime remove the need to cleanSweep, dust, polish and paint

Specific Objectives- SWEEP, SHINE, SCRUBDivide areas into zonesDefine responsibilities for cleaningTools and equipment must be owned by an individualFocus on removing the need to clean

PLAN SHOWING HOW AUDITING AGAINST 5S BECOMES A WAY OF LIFE

AreaResponsible PersonAuditors: Audit to be carried out by 3rd week of each month by named person and an assistantJulySeptNovOperationsArvindarjunSwastikSonaliWarehouseSreelekhaNareshSantoshRajatInventoryVenkatPrabhatSanjaySanjeev

Workplace Scan Score Card

Chart1

4

4

4

4

4

Five "S" Steps

Sheet1

Sort4

Straighten4

Shine4

Standardize4

Sustain4

Sheet1

0

0

0

0

0

Five 'S' Steps

Sheet2

Sheet3

9 Waste Radar Chart

% of Waste Before 5S

% of Waste After 5S

EMBED Sketch

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The Nine WastesPercentage of Waste

Overproduction

Delays

Transportation

Inventory

Motion

Processes

Defective Products

Untapped Resources

Mis- Used Resources

Before

After

Before

After

Before

After

Before

After

Before

After

Before

After

Before

After

Before

After

Before

After

% of Waste

100

90

80

70

60

50

40

30

20

10

0

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BENEFITSImprovements in:-Workforce moraleCompany imageHealth and SafetyMachine maintenanceQuality Productivity

Leading to Increased Competitiveness

Referenceshttp/:www.kdr-associates.com [Assessed on 07 Apr09]http://www.envision-hc.com [Assesed on 07 Apr09]http://www.nasfm.org [Assessed on 09 Apr09 ]http://www.cbi.nl [Assessed on 09 Apr09]Ho S.K.M. [1995-9], TQM: An IntegratedApproach Implementing TQ throughJapanese 5-S and ISO 9000, Kogan Page,UK (95 & 97 Ed.), HK Baptist Uni. (99 Ed.).Management & Marketing (2008) Vol. 3, No. 4, pp. 115-120.Hirano, Hiroyuki and Dr. J.T. Black. 1988. JIT Factory Revolution. Cambridge. Productivity Presshttp://www.businessknowledgesource.com/manufacturing/the_5_s_approach_to_lean_manufacturing_extended_entry_026157.html [Assesed on 20 Apr09]

*5S is the foundation, the building blocks, for a Kaizen approach to incremental improvement. 5S focuses on the elimination of wastes( Muda) in the work environment: to include the office environment as well as the manufacturing environment.

In simplest terms , it is the cleaning up of all the wastes so that the work environment produces what it wants, at the time it is needed in the correct quantities.

*5S was created in the Japanese manufacturing environment and literally stands for 5 Japanese words which begin with S:

Seiri, Seiton, Seison, Seiketsu, Shitsuke

When translated together mean a cleaning activity at a workplace.Aforementioned, 5S is an integral step towards Kaizen and Lean-site Manufacturing with the primary goal of being able to supply the customer ( internal,external) with the right product at the right time in the correct quantities.

*Its Ibana

What is the Japanese language

Japanese- seiri- EnglishNotes-

Etsu evana- notes- debashis

Wallet exercise- what is the purpose, sorting- tell them about Seiri

Use words like *Logistics:Pani 2 service excellence

Design Notes: Builds automatically.

Content: 5S background - Based on Japanese words that begin with S, the 5S philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality, efficiency and safety.*

*

*

*

*

*

*

*

*

*

*

*

*This model shows the inter-relationship of the 5S steps with the customers expectations of improved quality,improved safety, reduced nonconformance costs, improved product service options;thus, leading to a satisfied customer.Please note that the base of the pyramid is self-discipline-control. This step is key in maintaining the progress already achieved by the previous 4 Ss.

Also please note, that the deliverables are closely related to the deliverables of a Kaizen process.

*Discuss resistance-

BEFORE showing next slide,

Ask each person to answer/respond to/ or overcome their objection.

Show next slide*Discuss how benefits overcome resistance**

**