5s implementation -a snapshot
TRANSCRIPT
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Confederation of Indian IndustryCII-AVANTHA Centre for Competitiveness for SMEs1 20 February 2007
Confederation of Indian Industry
Confederation of Indian Industry
CIIAVANTHA Centre for Competitiveness
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Confederation of Indian IndustryCII-AVANTHA Centre for Competitiveness for SMEs2
5 S
( Work Place Improvement )
Implementation & Monitoringof
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5S is a basic, fundamental,
systematic approach for
productivity, quality and safetyimprovement in all types of
business.
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Who will Benefit by 5S
Any type of business, from a retail store to a power plant
-- from hospitals to television stations - all types of
businesses, and all areas within a business, will realize
benefits from implementing a Five S program.
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What will it cost me?
Improved Profitability
Efficiency Service
Safety
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Sort
Set in Order
Shine
Standardise
Sustain
Seiri
Seiton
Seiso
Seiketsu
Shitsuke
Elements of
5 S
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ObjectiveTo bring a cultural change in the
organization...
.Achieve through
Total Employee Involvement.
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1Sorting out :
Sort &OutWhat to Sort & What to
sendOut (REMOVE) ?
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1Sorting out :Sorting:
Identify,Segregate
Wanted & Unwanted things
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ORGANIZATION CHART FOR '5S' TEAM
CEO
5S' COMITTEE
COORDINATOR
DEPUTYCOORDINATOR
ZONE-1 ZONE-2 ZONE-3 ZONE-4 ZONE-5 ZONE-6 ZONE-7
TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER
TEAM
MEMEBERS
TEAM
MEMEBERS
TEAM
MEMEBERS
TEAM
MEMEBERS
TEAM
MEMEBERS
TEAM
MEMEBERS
TEAM
MEMEBERS
1Sorting out :Team members
are operators
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A Five S program is usually a part of, and the
key component of Visual Factory and
(Workplace) Management. And 5S and VFM
are both a part of Kaizen -- a system of
continual improvement -- which is a
component of lean manufacturing.
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Make zones by allocating a reasonable area to each leader
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RED TAG :-A Card containing detailed
information of unwanted things
with a given time limit for
further action to be taken.
To be used based on following
questions:
What is required ?
How much is required ?
When is it required ?
Where is it required?
Section / Area :-
Name of Item : Quantity :
Reason :-
1. Obsolete 5. Unnecessary
2. Defective 6. Mix - up
3. Scrap 7. Unidentified
4. Not in place 8. Others
Action :-
1. Move to Scrap Yard 4. Rectify
2. Locate properly 5. Return to Supplier
3.Segregate 6. Others
Target date of disposition:
Remarks :-
1Sorting out :5 S RED TAG
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Removing Red Tagged stuff
What Stuff would you Red Tag in these pictures ?
Think Break
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1 Sorting out
REDTAG AREA
Removal of unwanted things
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Methodology to Implement 1S: ( Contd.)Fix a date and time for Red Tag Campaign& carry out theaudit across all Zones.
Search & Identify unwanted things and tie them with a REDTAG.Other than product scrap, Red Tagged items should bemoved to respective RED TAG AREA.
All those items which are finally identified unwanted ones
should be reviewed by the review committee and decision
for disposing off should be taken within a fixed time(
MaximumTime Limit is 15 days).
1Sorting out :
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Zonal Leader & Members Photos
Photo
Current month view
Date : 11.01.08 Date :11.01.08
ZONAL MEMBERSZONAL LEADER: MR. ANAND KUMAR
ZONE: 2
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RED TAG CAMPAIGN
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RED TAG CAMPAIGN
Unused Raw Material due
to excess Inventory.
Created Free Space.
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RED TAG TARGETS
Types of items
Red-tag
targets
Physical areas
Inventory
Equipment
Floors, walkways, operation areas,
well, shelves, warehouses
Raw materials, procured
parts, processing parts, in-
process inventory, assemblyparts, semifinished products,
finished products
Machines, equipment, Jigs,
Tools, cutting bits, gauges, dies,
carts, conveyance tools,worktables, cabinets, desks,
chairs, supplies
Identifying Red-Tag Targets
1S
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DISPATCH DEPARTMENT
BEFORE AFTER
RACKS TO BE
REMOVED
Rack Removal
6x8 feet space released
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Example of 1 S
Before AfterHabit of accumulating unwanted things
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Example of 1Sat Office Area
Before After
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BEFORE
FTER
B f Af
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Before After
HP LP
Waterpump
House
Fly Ash
Silo
Operation Panel
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NO LEAKAGE
AFTER
BEFORE
BALCO POWER PALNT
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2S
Systematic
Arrangement
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Objective
Place for Every Useful Thing & Every Useful Thing is
on itsplace .
Arranging them in a Systematic manner.
Result: Reduces Search Time
(Systematic Arrangement)2S
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SEITON is important because it helps eliminatemany kinds of waste in the workplace
Motion WastePerson sent to find cart searchedfull factory
Searching WasteNo one can find the key to
the tool cabinet
Waste of Human EnergyFrustrated workergives up searching for template after two hours
2S
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Waste of Excess InventoryDesk drawers arefull of papers and stationary supplies
Waste of defective productsItems not kept
back in the same location so worker picks up
wrong piece for assembly
Waste of unsafe conditionBoxes of material
kept in the walkway, causing someone to trip
and get injured
2S
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Steps to do SEITON
Step ADeciding Appropriate location1.Principles of Storing jigs, tools, dies to eliminate
waste
2.Principles of motion economy to eliminate waste
3.5 S Map to decide location
Step BIdentifying location
1.Signboard Strategy
2.Painting Strategy3.Colour coding Strategy
4.Outlining strategy
Step 2 - SEITON2S
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Methodology to Implement 2SCheck What(Item Identification)?, Where( Location)?
& How Much( Quantity)? When( Time limit)? Before
actually practicing 2S.Decide appropriate location for every thing.
Display identification mark for every location.
Items stored should have the Identification Mark includingpurpose of storage & its review date.
(Systematic Arrangement)2S
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Direction for Respective Departments, Shops, Reception,
Canteen , Visitor Rooms, Meeting Halls . is clearly
marked and displayed.
Direction for Toilets and Water Coolers is self informative.
Display boards are available for Safety / Fire Prone Areas.
Display of Speed Control of the vehicle inside the factory
premises is adequate.
(Systematic Arrangement)
Presence of Good 2SContd..
2S
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Direction for Dispensary is clearly marked & displayed.
Serial numbers on Fans , Machines, Tube Lights, .are
present & visible.
Important / emergency Telephone Numbers are displayed
at appropriate locations.
Instructions for Safety / Quality Standards are clearly
visible.
Shadow Boards are available at the appropriate locations.
(Systematic Arrangement)
Presence of Good 2S( Contd.)
2S
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Benefits of 2S
Faster retrieval of things, result in Elimination ofSearch Time.
Opportunity to correct the abnormalitiesfaster as
visibility improves by system itself.Space Savingby systematic arrangements.
Efficiency of work improves as things are available
when they are actually needed.
(Systematic Arrangement)2S
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Kaizen No. 1
Kaizen Theme:Easy identification of pipeline
Problem: There was no
identification on the pipeline with
respect to the pump
Benifits:
Reduction of time for identifying the
pipeline with respect to pump.
0
5
10
15
20
25
30
35
Before After
Time in minMin
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Right Things in the Right Place.
2S
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Before
After
(Systematic Arrangements)
Pre-Fixed
Locations
2S
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Shadow Boards2S
Only shadows on board .. Empty boardShadow board with tools
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Kaizen 3
Zone no:2
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Kaizen 3Zone No.2BOILER
ThemeCOLOUR CODING OF ALL
PRESSURE GAUGES IN MILL AREA
ProblemEARLIER THERE WAS NOCOLOR-CODING OF PRESSURE GAUGES
IN MILL AREA.OPERATORS ARE NOT
ABLE TO PREDICT THE SAFE WORKING
CONDITION OF THE RUNNING
EQUIPMENTS.NOW COLOUR CODING OF
96 NOS,. OF GAUGES HAVE BEEN DONE
Benefits
IDENTIFICATION TIME REDUCED.
SAFE WORKING RANGE OF HYD. PUMP WAS
PREDICTED RESULTING IN LESS FAILURE.
Costof Implementing : RS.10/- PERGAUGE.
Zone no:2
BEFORE
AFTER
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BALCO POWER PLANT
Identification
of thevalve ON-OFF
position
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EASY IDENTIFICATION
BALCO POWER PLANT
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Kaizen No. 1
Kaizen Theme:Easy inspection of water pr. gauge
Problem: Pressure gauge was at 25
mtr height .The pressure has to
check twice in a shift.
Benifits:
Movement reduced.
CPP-1/zone-4sz-5
Before
After50
00
10
20
30
40
50
60
Before After
2 S
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Example of 2S at office area2S
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Solution / Benefit:
All the Pipe Lines were labeled, it
help the operators to operate in
safer atmosphere and it also
reduce time of operation
Problem:
Earlier, Pipe Lines were notlabeled due to which operation
was not understood
Kaizen No. 5
Kaizen Theme: LABELING OF PIPES
Benefits -
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Benefit:
It help local operator in proper
identification which save time.
(5 mins approx.)
Problem:
Earlier there was no properindication of pneumatic valve
open or close
Kaizen No. 1
Kaizen Theme: Valve open and close visual indication.
C D
3 S
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3 S CLEANLINESS)
ShineEverything
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3 S
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Objectives and Benefits of Practicing3S
Provides dust free environment.
Creates safe & healthy work place.
Ensures higher quality of work & products.
Increases the efficiency & life of equipment .
Improves Visibility to identify abnormalities.
3 S Shine everything )
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7 types of
Abnormalities
Unfulfilledbasic
conditions
Inaccessibleplaces
Unsafe places
Unnecessaryand Non-
urgent items
Quality defectsources
Contaminatedsources
Minor Flaws
7 Types of Abnormalities
3 S
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Example of 3Sat Shop Floor
3 S Shine everything )
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Before
After
BHARAT ALUMINIUM COMPANY LIMITED
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Problems:
View before thermography showing a
header looks externally well insulated,with no Thermal Loss
If survey done through IR gun gives
satisfactory result
Solution: Oil stand, color coding of oil drums& Equipments, Oil measuring can
Kaizen Theme: Finding abnormalities through Thermography
Before
A
F
T
E
R
Costof Implementing : Nil
Benefits
The maximum observed temperature
is very high.
The loss on evaluation = 0.04
KCal/kWhr (Approx)
Revenue loss = 5000 Rs PA
Thermography shows the hot spot at various
locations
BALCOKaizen No.1 Kaizen at Turbine area
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Solution / Benefit:
Gives visual identification of location of
leakage
Loss in terms of heat & cost is known
Creates awareness of the employeeGives the commitment towards work.
Problem:
Earlier leakages were noted down inthe defect lists, also the losses in
term heat & cost were not
evaluated.
Kaizen Theme:To create awareness about the leakages with proper quantification
-(Harshal Ambulkar)
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