M.Sreedhar Patnaikincharge- process & QA

Visakha Steel Allieds

What is work place ? “Work place is where one works” “Where there is an out put” “Where there is creative activity” “Where values is being added”

It is where one spends the longest part of his living time.

Importance of workplace in one’s life On an average one spends his whole day

as below: 25 – 30% time for sleeping 5 – 10% time for having food 15 – 25% time with family 5 – 15% time for travelling 35 – 40% time for workplace That is, about 50% of our wakeful time,

we spend in our work place.

How is your work place ? Threatening (or) Inviting ? Lovable (or) not likeable ?

Can we make our workplace excellent, so that life is fulfilling and enjoyable. And we and our Organization become excellent….

Yes: We can through 5S

Your workplace should be an enabler: Because good workplace is what enables

us to Earn our salaries Provide for our families Given good education to our children

and improve our quality of life

“ I earn my salary by adding value to my Organization’s products”

Why is your Organization’s health important to you ?

A healthy Organization showers prosperity on its employees.

How does good workplace help your Organization?

My workplace helps my organization to create products, manufacture products, reach them to customers, execute growth plans, provide service to customers. and

Create value for customers, our organization, my co-employees and all other stakeholders. If it is not in excellent condition, our organization would also not be.

Arrange all tools at one place it is easy to find any body

If it is good it would add more

value to my Organization

Workplace becomes good through 5S “I don’t have to wait for materials I can

get any tool I need in seconds and I don’t get tired through heat, sweat and poor ventilation:

How ? When: I organized my workplace well

This is 5S workplace

The physical and psychological “ENVIRONMENT” become better

“ATMOSPHERE” became serene. Activities got “STREAMLINES” and “WASTAGE” where avoided

This enabled me and my organization to improve performance

Bad environment

Good environment

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Just as your body and attire indicate your personality, condition of your work place also indicates your personality

Soul

Body

Attire

POSITIVE GROUP ENGAGED IN 5S

I consider my workplace as a symbol of myself and an extension of my personality, It is like the shirt I wear I do not like to wear dirty, smelling, bad quality shirt, it is below my dignity, same about my work place.

For a good physical & psychological environment

We need Orderliness Good Organization Cleanliness No wastage of time No wastage of energy No wastage of material No pin picks like heat, poor ventilation,

bad light, dust, dirt etc., As Also A Good Culture

A highly negative, argumentative stressful shop floor is unhealthy

The Psychological environment should be…………………..

Fulfilling Acceptable to the employees Satisfying Where you are seen as efficient and

performing Where you feel proud to work

5S Cannot be implemented with out proper culture

• I always look forward

to have happy

environment in my

work place•5S has made me

take care and see

that me and others

are happy with what

is going on in my

workplace

•5S enables me

and others to

derive immense

satisfaction

What is 5S ? “5S is a simple method for achieving

excellence in your workplace using A FIVE STEPS approach” 1st S : Seiri (Sorting):- Ensure all needed

items are available and keep away all not needed items.

2nd S : Seiton (Systematic arrangement):- Arrange only needed items such that you can always access them easily.

3rd S: Seiso (Spic & Span):- Keep them neat and tidy.

4th S: Seiketsu (Standardization):- Make the best way the standard way; and do it every time in the standar way

5th S: Shitsuke (Self discipline):- Make this a habit

Do not make the mistake of thinking that 5S covers only “THE PHYSICAL ENVORONMENT”

5S operates at The physical level The data level & The systems level 5S

System

level

Data

leve

l

Physical level

Please note :-1) 5S starts with sorting2) Then arranging things systematically and neatly.3) 5S is not enforced by bosses.4) 5S learning is complete with having total self

discipline and habit formation.5) 5S should be carried out in every nook and

corner of the organization.6) No body is exempt from doing 5S it covers all

levels.7) It is continuous activity carried out by you

happily every day all your life.8) In fact 5S never ends Boss enforcing is not a 5s approach Good 5S 5S should be everybody’s concern &

responsibility.

5S addresses :-

ABNORMALITIES :- “Whatever is not correct and not in the best condition”

WASTAGES :- “Wastage does not added value to the product but adds to cost”

TYPES OF WASTE :- (*) TIME (*) SPACE (*) MATERIAL

o All leading to money wastageo An abnormalityo Is anything that is not as per design intention or

Expectation:- Loose bolts and nuts. Damaged body, foundation, floor, wall etc., Dents, Scratches etc., Rusted components. Misalignment of materials, boxes etc., Unnecessarily open doors. Hanging and loose wires. Dirty switch boards. Machine not running properly. Leakages. Noise, rattling, vibration. Cobwebs, bad toilets. Uneven movements. Etc.,

List abnormalities in your workplace

continuously & photograph them before and after

correction, so that the impact of correction is

visible.

Physical abnormalities

Damage Visible defect Rusting Incorrect position Bad appearance Leakages Screws/bolts/nuts Not tight Noise Vibration etc.,

Functional abnormalities

Equipment not Functioning as per

designing or customer requirements.

Leading to problems Like unsafe operations

low/high speed, poor output, over/under temperature, insufficient pressure.

Heavy wear and tear etc.,

AVOIDABLE WASTAGE :-Include following in your checklist:- Power ………………… Power wastage Compressed air …… Compressed air wastage Water ………………… water wastage Steam ………………… steam wastage Oils ………………… oils wastage Lubricants …………… paint & Lubricants wastage Consumables Production material Any other special item in our factory

TIME WASTAGE :-Time is Money! Idle time of machines. Time spent in searching for tools. Set-up times do not add value to product or

customer. Chasing people, tools, materials. Searching for paper, documents and manuals. Waiting time for men and machines Re-work on which you repeat the time spent by

man and machine.

Required additional avoidable capital investment, build in shop floor, stores, shelves etc.,

Can lead to accidents. Heads to inconvenience. Makes it difficult to trace required item in

a bunch of items.Space occupied by unwanted items can be utilized for keeping necessary items in an easy accessible fashion

that maintains its quality and improves its life.

Unwanted material lying here and there, and deteriorating over time.

Over – Production. Unnecessary inventory that adds to working

capital. Defects. Excess material for processing, like too much

raw-material for small components. Over-usage and leakage of consumable.

Material wastage costs a lot to the organization

5% saving in material cost can improve profit by 25 to

50% more

Example : -

2) This is an out door storage for raw-materials like sheets, rods, angles, channels etc., will they not get corroded and lose their properties over time? Do you agree this should be improved.

1) If we think unsafe storage place for paints, oils and Lubricants. Do you realise how much value and money is lost because of such poor storage and upkeep besides begin a safety hazard.

Goal

Money

TimeSpac

eM

aterial

Assets

1) Prepare the list of items that are needed in your workplace.

2) List out needed items that are not available.3) Ensure availability of needed items.4) List out unnecessary items available in your

workplace.5) Segregate unnecessary items into a. Those needed less frequently or rarely.b. Needed by some other department.c. Not sure whether needed or not & d. Not needed / scrap

6) Get rid of unnecessary items from the workplace by giving away to those in need. Creating a special location (Red tag area) for doubtful items for decision making. Keeping rarely needed items easily accessible in stores and disporting off unwanted items.

7) Present unnecessary items from entering.8) Do not provide any space for unnecessary

items. TARGETS OF SEIRI:- (A).What should be available:- Items that are needed every day for ensuring

product and efficient working. Items needed in an emergency. Items that are needed every day for good

product and efficient working.

Unwanted items Superfluous items Idle equipment / tools Unsold products Items that are not needed in your

workplace Items kept because there is no pace

available else where

• There may be items that have good value but are not needed at my work place. It is better to ask my superior. “what should I do with them:

• I always ask my self

• # Do I have items I don’t need at my workplace

• #Which not needed items are there preventing me from working well.

• # Do I have items at my place that others need and that make them struggle to perform well?

•Be careful

while

discarding

items

While doing Seiri:-

In your enthusiasm to so 5S well ensure that you or the organization do not get into difficulties later on by errors in execution.

Take the help of higher authorities to decide on doubtful items.

One should not be in trouble at a later because of a needed item being discarded.

SEITON:Place for every thing & Every thing in its place

Goal

Easy accessibility of needed items

SEITON IS:- Arranging segregated items in a standard fashion Any one can retrieve any item, any time with

minimum search time and They do not get damaged or dysfunctional through

careless storage.

STEPS OF SEITON:-1) Do SEIRI thoroughly throw away items. Don’t include

them in SEITON.2) Decide where to locate each necessary items.3) Decide how to locate these items so that they can be

“easily traced” and also “do not get damaged” or “Deteriorated”

SEITON:- All items needed by the operator such as tools, jigs,

fixtures, consumables, production items bins, etc.,

Target of SEITON

Nearness of storage location

according to frequency of

usage

Storage method (Packing) as per

the life and safety requirements of the item and its

users.

On the item

Provide Name, code & Add

All the place of storage,

including its temporary

location

In a common record,

register plus computer.

How to record address:- No ambiguity should be there on what is the item No confusion between different items. The permanent, as well as present location

should be clear. A standardized unique code no. and name should

be given for each item.

Store with good addressing system appropriate labels/ stickers; addresses; names; carefully numbered racks and well- designed code number for items.

See also that the data is stored in a computer and recorded in a register.

SEISO : Spic & :Spam

Attitude & Behaviour:- are the sources of all dirtiness / untidiness

It is necessary to train our behaviour to reject untidiness and correct it all the time.

Learn to react to all that is not up to the mark and correct it without waiting for some one else to do it.

Often we are not keen to handle cleaning equipment ourselves as it is distasteful. Leader has to show the way by himself carrying out seiso.

Defects are revealed white cleaning. Mend them as soon as you notice them.

Is it right that some one spoils the workplace and some one else cleans it ? That is not the way to achieve workplace excellence.

SEISO : Spic & Spam

STPS OF SEISO:1) Identify which parts to be cleaned each shift /

twice daily, weekly, monthly etc.,2) Plan for systematic daily or periodic cleaning of

all nooks and corners of the zone/ whole plant.3) Prepare a cleaning calendar and follow it

regularly

Every one has to contribute to maintain his/ her workplace clean and tidy. While doing SEISO learn to eliminate all root causes of dust

and dirt

4) Ensure cleaning material and cleaning tools are available at any accessible place.

5) Carry out SEISO systematically.6) Attend to defects that are revealed while

cleaning.7) Identify and remove the root causes of such

defects.8) Identify and remove the root causes of dust and

dirt.

Cleanliness

Cleanliness Good

Psychological environment

Hygiene

Timely correction of

defects

Exposing hidden defects

Safety and removing hazardous

Targets of

SEISO

TARGETS OF SEISO:-

Machinery

1) Clean: Surfaces Sides

Insides All around

3) Safety: Identify safety hazards like loose foundation,

excessive vibration etc.,

5) Timeliness; Did you discover and rectify problems

before it was too late ?

2) Expose: Hidden defects while

cleaning cracks, rusting damages.

4) Hygienic: Look out for bad smell, pollution ensure

ventilation, lighting etc., 6) Psychological

environment: Is the organizational environment

conductive to do all the above?

Standardization:

Goal

Maximize benefits.

(when every one does a thing the

standard way. WASTE and

COST are minimal

•Sreedhar always

produces in best quality

and highest productivity

let us see how he does it

and accept is as the

“STANDARD:

• Do not impose standards that are difficult to stick to seiketsu standardizes the best results achieved through seiri, seiton and seiso. Continuous repetition of first 3S will create a work place that is

•SAFE, COST

EFFECTIVE, INVITING,

ACCEPTABLE, NOT

FRUSTRATING TO

WORK WITH AND

EXCELLENT IN ALL

RESPECTS.

Through Seiketsu:-

Set standards for all that is repetitive.

Hone and polish these standards continuously.

Develop cleaning calendars, visual controls, check lists

Learn to expose problems.

Propagate/educate regarding safety measures, and

Conserve resources.

STEPS OF SEIKETSU:1) Identify the way different people are doing an

activity.2) Discuss and choose the best way3) Make this the standard method once everyone

accepts it.4) Convert this into a written standard, giving a

reference code number.5) Ensure that everyone does the same work only

as per the standard.6) After accepting it as the standard, review it from

time to time and improve it as necessary.7) Identify the weaknesses in the standard and

upgrade them.

TARGETS OF SEIKETSU:-

FREQUENCY: Those elements of work, which are carried out frequently need to be standardized so that time taken and consumption of other resources can be minimized.

SAFETY: Work done wrongly can lead to accidents. COST: Work in many different ways as per each

individual’s idea can lead to high wastage and cost FOCUS OF SEIKETSU:(a). ITEMS, (b). PROCESSES, (c). SYSTEMS1) Loose top cover in a pressure vessel is

“DANGEROUS”2) Loose electric wire, poor plugging and bad jointing

leads to electric shock and injury to people.

SELF DISCIPLINE: Goal

Sustenance

5S andThe improvement

process become a habit and you carry it an

every day

SHITSUKE:- Propagates sustenance of 5S through habit formation.

Human nature is to ignore the rules.When 5S becomes a habit , one is directed internally and rule takes over automatically.The is no need to supervise, inspect and correct your activities.

DO EACH ACTIVITY AS PER THE STANDARD AND FOLLOW ALL STEPS.

RULE IS A RULE AND RULE FOR ALL Rule is to be formulated by arriving at a

consensus of everyone so that all objections and concerns are taken into account.

Rule is to be easily understood in 10 seconds perfectly through “VISUAL CONTROLS”. Otherwise there may be errors in following it.

One should feel for the rule and follow it oneself pressure from the top.

A rule is not supposed to be broken by anyone every relevant person should be covered by the rule.

STEPS OF SHITSUKE (All self governed steps):

1) I know 5S and follow it EVERY DAY from the time of starting to work and repeating it when I close for the day.

2) I keep myself tidy and follow the dress code.3) I do my routine activities as per the STANDARDS

only.4) I keep my workplace SPIC & SPAN.5) I strictly follow safety rules.6) I am always searching for “ABNORMALITIES”7) I am always looking for how to “SOLVE” them.8) I am 5S PERSONTargets of

SHITSUKE

EVERY ONE IS 5S PERSON

EVERY PLACE IS A 5S PLACE

Check list:- Prepare a check list for maintaining your work place while starting and before leaving your workplace.

Check…… Workplace cleaned before / after shift Previously listed “ABNORMALITIES” are corrected. No unwanted material in the workplace. Inspection of the machine and tools, jigs and fixtures

before starting. Checking for lubrication, leakages, loose nuts / bolts,

noise, vibration etc., All tools ready at the workplace (or back to their

place of storage). Safety equipment like hand gloves, safety

spectacles, safety shoes, etc are on Toilet cleanliness etc.,

SELF AUDIT(CONDUCT SELF-AUDIT): Your mid is your judge. Ask it whether you have done it right

Daily 5 Minutes 5S In the initial stage it takes time to follow 5S once

it is sustained it becomes 5 minutes 5S daily.

• Eh! Now a days I love my machine like my child. I take care of its needs. I clean it up and make it look good. It loves me too. It never troubles me no misbehavior, no breakdowns.

• Why con’t I extended 5S to my home?

• Yes, I extended 5s to my home. My wife became much more loving and cooperative after that

THANK THANK YOUYOU