5s the way

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Introductory training

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Anyone feel like this now ?

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What is your opinion ?

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Not pleasant

Uneasy

Irritating

Disturbing

Unsafe



Searching…………


What is 5S?

Warehouse

Boss, Look at my

Master piece ?

! ? # @ & *

$ % !

5S is not to produce aesthetic effects to impress others


A medicine, easy to take and can cure most problems effectively. It

has no expired date and no side effects

5S - An effective cure to problems

A company is just like human body.

It has to be maintained to its best condition!


5S – Surface out the problems

more than anticipated

5S


5S in Engineering

To eliminate the wastes that result from “uncontrolled” processes.

To gain control on equipment, material & inventory placement and position.

Apply Control Techniques to Eliminate Erosion of Improvements.

Standardize Improvements for Maintenance of Critical Process parameters.


Productivity

OutputProductivity = -----------

Input

Productivity can be improved in two ways

For the given output reduce input

Increase output for the given input


Why productivity ?

To achieve the maximum output from the given input in order to increase

the profitability and to reduce the manufacturing cost

Why low productivity ?

Target

Actual

Gap Wastes


Every thing

Takes time

Costs Money


Value add work vs Non-value add work

All work is either

Value Add

Transforms material or information to meet

the true desires of an external customer

Non-Value Add

Any activity that does not change the state of product / information

to meet the customer requirement

Control

Information

Administration

Other


Which of these activities add value?

Looking for parts

Building products

Inspecting

Testing

Rework

Delivering services

Packaging

Shipping

Searching for info

Filling out forms

Entering data

Answering customer questions

Stocking shelves

Training

Selling


Low Hanging fruit

Where do you think you will

find the “low hanging fruit”

when you begin your

improvement efforts?

By increasing the 5% of value-

add activities?

By reducing the 95% of non-

value-add activities


Fundamental principle of process improvement

Anything that does not add

value is waste, and must be

reduced or eliminated


In lean manufacturing waste is anything that adds to the time and cost of

making a product

but does not add value to the product from the customer’s point of view.

Value-added activities transform the product into something the customer

wants. In manufacturing this is generally a physical transformation of the

product to make it to conform to customer expectations.

Figure shows a simplified version of the steps required to make a steel

subassembly..

Delivery

Buffer Buffer Buffer Buffer Buffer BufferStock yard

Blast & PrimeCutting &

marking

Panel lineBlock Assy Block

painting

Block

outfitting

Block

errection

Non value

added

value added

TimeRaw material Finished goods

WASTE :


Types of wastes

There are eight types of wastes

1. Over production

2. Inventory

3. Conveyance

4. Defect production

5. Process related

6. Operation related

7. Idle time waste

8. Under utilized People


1. Over production waste

Making what is unnecessary, when it is unnecessary and in an unnecessary

amount


OVER PRODUCTION

Large batches and Inventory

Planning full utilization of machines and Labors

Producing more goods than market demand

Goal “Produce as needed when needed”


2. Inventory waste

It is when anything (materials, parts..) is retained for an length of time. This

includes finished goods as well as in process materials

Inventory is terrible

Inventory is a liability

We want zero inventory

Inventory is to be minimized

Reduce inventory

Inventory is bad, bad, bad…


INVENTORY

High stocks of raw materials, WIP & Finished goods

Additional space requirements

Dis-order


Cost of Inventory

Cost to borrow money

Insurance

Space

Loss due to damage and

obsolescence

Cost to count it

(over and over)

Cost to move it

(over and over)


3. Conveyance waste

Created by conveying, transferring, picking up / setting down, piling up and

moving unnecessary items


TRANSPORTATION

Unnecessary movement

Extra handling

Moving Inventory

Goal “There is a place for everything, and everything has its place”


4. Defect production waste

Waste related to costs for inspection of defects in materials, processes,

customer complaints and repairs

Defects

Primary defects Secondary defects

• Processing omissions

• Processing errors

• Missing parts

• Wrong items

• Adjustment errors

• Miss operation

• Work piece setting wrong

• Wrong work piece

• Incorrect equipment setup

• Other errors


DEFECTS

Large delays for trouble shooting

Costly network

Dissatisfied downstream customers

Goal “Doing it Right, the First Time”


5. Processing related waste

Unnecessary processes, operations traditionally accepted as necessary and

process errors


PROCESSING

Poor machine maintenance

Unnecessary processing steps

Longer lead times

Goal is to “Reduce over-processing by doing things right the first

time”


6. Operation related waste

Unnecessary movement, movement that does not add value, movement

that is too slow or too fast


MOTION

Incorrect Layouts of office, Factory etc.,

Lack of proximity of machines

Off-line resources

Goal is “Reduce motion through proper planning, executing, and

maintaining your process”


SSrinivasu

7. Idle time waste

Waste of which the causes originate in waiting from materials, operations,

conveyance, inspection as well as the idle time attendant to monitoring and

operation procedures

Why doesn’t

it start?


WAITING TIME (DELAYS)

Watching machines work

Long set-up and lead times

Goal is to “ Be accountable for information needed and

information delivery”


8. Under utilized Manpower waste

Underutilized People – Lack of focus or systemic

wastes

• Lack of ownership of tasks, unnecessary

assignment

• Lack of goal alignment

• Lost creative insights

Goal is to “Communicate expectation, provide mentoring ,

support, and empowerment”


Our Goal when dealing with “WASTE“

Goal = Get ever closer to zero

Zero defects

Zero scrap

Zero rework

Zero receiving rejections

Zero downtime

Zero inventory

Zero handling

Zero paperwork

Zero mistakes

Zero absenteeism

Zero waste


Sort Store Shine Standardise Sustain


SORT


Sort out – Required item & waste item

SEIRI


Purpose of having SEIRI

Create valuable and safe working space.

Prevent mistakes: miss-usage, miss-handling, miss-

transport etc.

Prevent material deformation. Prevent dead lock of fund

and capital.

Create spacious feeling at work place.

Seiri - The approach to raise work efficiency


Action for SEIRI

• Sort out and take out unnecessary

items and discard them

Remember : Bogi


Action guideline for SEIRI - Steps

Seiri is to perform clearing up (sort) activities with group participation.

Sort out Wanted items and Unwanted

items.1

Dispose off (send for treatment) the

unwanted items2

Provide streamlined, safe and proper

storage conditions for wanted items.3


RED Tag - Model

RED TAG

Classification 1. Rawmaterial

2.Work-in-progress

3.Conponent part

4.Finished product

5.Machine / Equipment

6.Mould / Jigs

7.Tools/Fittings

8. Others

Name of the item:

Order number

Quantity/ Value _____ items , Value / item______ , Total :

Reason

1.Unnecessary

2.Defective

3.Non Urgent

5.Left over material

6.Unknown

7.Other

Section reponsible _____ Dept. , Section______ , _______ Group

Action

1.Eliminate

2.Return

3.Move to red tag storage

4.Store seperately

5.Other

Completed

DateTag atttached date Action taken date

Reference no.


RED Tag


Separate the wanted

& unwanted

Junk & waste Repairable Wanted

Discard To the next S

No use Repair & use

Action guideline to follow SEIRI

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Consequences of not following SEIRI

Keeping unnecessary things needs more space

It becomes difficult to say which is needed and not

Cleaning activity added on the unnecessary parts

Some time it needs maintenance and it adds cost

Creates safety issues in some cases


P

R

O

PE

R

Z

E

M

E

NT

B

ZA

RR A N GZ


Arrange in proper order for easy use.

SEITON


Purpose of having SEITON

Eliminate unproductive “search time”.

Create and claim back valuable work space.

Compress stock quantity.

Create systematic, direct visual effect layout (visual

management) at work place.

Seiton - The approach to systematic arrangement


SEITON


• Arrange necessary items in proper

order so that they can be easily

picked up for use

Action for SEITON

Remember – Books arrangement in Library

http://images.google.co.in/imgres?imgurl=http://users.ox.ac.uk/~shug1356/library.jpg&imgrefurl=http://users.ox.ac.uk/~shug1356/clocks.html&h=507&w=676&sz=77&tbnid=BgJVRvc4A-EJ:&tbnh=102&tbnw=136&start=2&prev=/images%3Fq%3Dlibrary%26hl%3Den%26lr%3D%26ie%3DUTF-8%26sa%3DN


Action guideline for SEITON

Keep the things in order1

Every thing in its place2

The things to be easily reachable3


SEITON – It is simple to remember


SEITON


Some 5S Examples

Before 5S

After 5S - Cleaned,

organized and drawers

labeled (less time and

frustration hunting)


5S Examples - Sort, Set in Order

See the difference?

1. Sort - All unneeded tools, parts and supplies are removed

from the area

2. Set in Order - A place for everything and everything is

in its place


The Good, Bad and the Ugly

First the Bad and the Ugly - Life Without 5S


The Good


Consequences of not following SEITON

Things are seldom available when needed,

More time spent for locating misplaced things

Defective & good items / similar looking items get mixed up

Prone to Loss of production

Excess inventory

Pressure for more space

Items are lost


CLEANING


Clean your workplace completely

SEISO


Purpose of having SEISO

Remove untidiness, prevent dust accumulation.

Expose existing & potential problems.

Promote preventive maintenance.

Prevent accident, secure quality.

Make a clean & pleasant work place.

Study cleaning method

improve cleaning efficiency

eliminate the needs of cleaning.

Seiton - The approach to enhance work quality


Cleaning means

Checking

Eliminating the causes of defects

Maintaining optimum conditions

Attention to details to achieve the

best conditions


• Clean your workplace / surroundings

thoroughly so that there is no dust on

the floors / machines & equipment

Action for SEISO


Place Item When How Who

Action guide Guidelines for SEISO

Establish what to clean , cleaning method & responsibility1

Real cleaning is something that comes from the heart 2

Make cleaning everyday a habit3


Consequences of not following SEISO

Dust / dirt will affect the machine performance

Cleaning reveals hidden problems which may get

overlooked otherwise

Dust & dirt will affect performance &

aesthetic quality

Unpleasant work place will result.


STANDARDISATION


Maintain a high standard of house keeping and workplace

SEIKETSU


Purpose of having SEIKETSU

Set up clean and comfortable work place.

Improve, maintain and aim for higher level of

achievement.

Establish higher level of company image.

Bring up product superiority (indirectly).

Seiton - The approach to safety & work enthusiasm


Action for SEIKETSU

• Establish procedures & standards to

maintain 5S and perform regular patrol

to all areas & continually audit the 5S

progress


Action guidelines for SEIKETSU

Make standards for clean work place

Convert standards to VCS

Facilitate identification of deviations for immediate

corrective actions


Checklist for 5S – Office / Shop floor


Consequences of not following SEIKETSU

More chance for going back to old condition

“Things get measured, will improve”


TRAINING & DISCIPLINE


Train people & follow good house keeping disciplines

SHITSUKE


Purpose of having SHITSUKE

To cultivate good habits and sustain the 5S culture.

To maintain a group of well disciplined work force.

Abiding to standards and ruling to secure a clean, safe,

healthy, happy and efficient work place by everyone for

everyone (total work force).

The approach to discipline group works &

continual improvement.


Action for SHITSUKE

• Cultivate spirits of self discipline and

self awareness to maintain, encourage

and continue 5S activities and

sustaining it with timely motivation,

training and sharing of working

results.


SHITSUKE - Discipline


Action guideline for SHITSUKE

Train people to follow good house keeping disciplines

automatically

Follow discipline in maintaining 5S and make it a habit

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SEIRI SHITSUKE

SEITON

SEIKETSU SEISO

2

1

3

4 5

Summary - 5S concept


The implementation of 5S

Step 1 Start with the Leadership Team

Step 2 Build the Infrastructure

Step 3 Launch Communications

Step 4 Train Teams in 5S Techniques

Step 5 Begin 5S Pilots

Step 6 Establish Best Practices

Step 7 Develop a Full Roll-Out Plan

Step 8 Continually Evaluate & Adjust


5S – Visible benefits

Improves on-time delivery

Improves quality / reduced defects

Increases productivity , Reduces lead times

Reduces waste in materials, space and time

Reduces inventory and storage costs

Reduces changeover time , Reduces equipment

downtime

Improves safety


Action on Ground

Daily monitor and improve the score

Put 5S Score yourself or do it by cross audits

Spend daily first 10 minutes for machine cleaning

Every Saturday spend 1 hour for Seiri & Seiton ( 2s

Activities )

Monthly once conduct red tag campaign to remove

unwanted / scrap materials


Can we find areas of improvement

in your Work place ?

Action on Ground


You have to decide

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d i f f e r e n t i a t e………..

Thank you

cell : 9976774372, 9344689828

5s the way

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