management-5s system-introduction to 5s system.ppt

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  • SeiriSeitonSeisoSeiketsuShitsuke

  • 1980195019701960U.S.AJAPANINDIAQuality Improvements

  • 1. 5S Principles Elimination of waste Every body is involved, Co-operative effort Attack root cause Human being is fallible

  • 2. Objectives Improve housekeeping Make every individual responsible for housekeeping Beautify by simple means Productivity improvement by saving time, space etc.

  • 3. 5SsSeiri - SortingSeiton - Systematic arrangementSeiso - Cleaning Inspection while cleaningSeiketsu - StandardizationShitsuke - Self Discipline

  • 5SIf we do not do 5S, we cant do anyother work efficiently. They are features which are common to all places and are the indicators of how well an organization is functioning.

  • COMMON MIND SETS

    Its an additional burden. Too busy to do 5S activities. Why clean it? It will get dirty again We cannot change the existing setup. More work pressure No time for these things 5S means cleaning up the desk

  • SEIRI = Sorting Just in Case to Just-in-TimeMeaningidentify necessary and unnecessary items and eliminate the unnecessary items

    Activity:Establish a criteria for eliminating unwanted items. - Eliminate unwanted items either by disposing them or by relocating them.SuccessArea saved or percentage of space availableIndicator

  • SEIRI = Sorting Fight with habits

  • SEIRI = Sorting 3 Categories - Item RequiredX Item Not Required? Undecided Move to Red Tag Holding Area

  • 1. Item is not needed2. Item is needed however quantity in stock is more than what is needed for consumption in near future3. Item is needed but once in a blue-moon

    4. Contingency Parts Critically decide the quantity of contingency parts to be retained and criteria for such partsSeiri = SortingWhat is unnecessary

  • Frequency of useStorage Method*Things you have not used in the past one yearThrow them out*Things you have used once in the last 6-12 months Store at distance OR Keep in storeLOW*Things you have used only once in the last 2-6 months Store it in central place in your zone*Things used more than once a month Store it in central place in your zoneAVERAGE

    HIGH*Things used once a week Store near the workplace*Things used daily or hourly Store near the workplaceOrganization

  • Seiri = SortingIdentifying unnecessary1. Parts & Work in Process (WIP) Things fallen back behind the machine or rolled under it Broken / some items inside the machine Things under the racks/ platform Extra WIP Stock of rejected items Items accumulated over period for rework Material awaiting disposal decision Material brought for some trial, still lying even after trial Small qty of material no longer in useContd..

  • Seiri = SortingIdentifying unnecessary2. Tools, Toolings, Measuring devices Old jigs, tools not in use are lying Modified tools, tooling for trial, are lying after trial Worn out items like bushes, liners, toggles etc. lying Broken tools, bits, etc. may be lying Measuring equipment not required for the operation being performed, is lying3. Contingency Parts Many times storage place for contingency parts become a last refuge for broken parts, surplus items and things nobody is likely to useContd..

  • Seiri = SortingIdentifying unnecessary4. Shelves and Lockers Shelves and lockers tends to collect things that nobody ever uses, like surplus, broken items, used tea-cups etc.5. Passages and CornersWIP material waiting for decision or dispatch Dust, material not required seem to gather in corner6. Besides Pillars and under the stairs These places tends to collect junk, spittoon etc.7. 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..

  • Seiri = SortingIdentifying unnecessary8.Floor, Pits, Partitions Defective parts Protection caps, shoe covers Packing material, stickers, barcodes, cut-leads Hardware items, small items, runners, plastic granules Even tools, toolingItems dropped on the floor are never picked9.Computer Hard Disk Many unwanted, outdated, temporary files pile upOld dated mails still remaining in inbox and sent itemsDeleted mails not being purged when closed Recycle bin not emptied

  • Seiri = SortingTAGGING

    GIC

    RED TAG

    TAG No ______________ Date _________

    ITEM NAME________________QTY ______

    Tag Created By: _________________________________

    Reason: ________________________________________

    ______________________________________________________________________________________________

    Decision Date: ___________Decision By: __________

    To Scrap To Reuse after Salvage To Dispose

  • Seiri = SortingImprovement methods1. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system eg. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for systemeg. How to perform Seiri (sorting)

    3. Check ListA check sheet is used to decide what sort of main systemand sub system are necessary.

  • Sheet1

    1 - S CHECKLIST - SHOPFLOOR

    PLANT:DATE:

    AREA: PERSON RESPONSIBLE:

    No.PARAMETERSEXCE.GOODAVG.BADPOOR

    POINTS54321

    1Is there any UNWANTED item present in area

    2Is there any item more than required

    3Is there any item on different location

    4Is there proper Red Tag Area identified

    5Is the list of all items in Red Tag Area available

    6Is there any classification done for Wanted items

    7Is there any item not used for more than a year

    8Is there criteria present to eliminate unnecessary items

    9Is there any unwanted dirt/dust present

    10Is there any leakage present (Air, Water, Oil or Material)

    11Is there any defective item present or Unsafe item in the area

    12Is there any spilled item on the floor

    13Are all Equipments, Jigs & Machines working OK

    14Is there minimum 20 % storage free space available

    15Are People working in the area aware about 1 - S

    OVERALL SCORE

    REMARKS:

    NOTE: MINIMUM 75 % REQUIRED FOR NEXT STEP AUDIT

    Sheet2

    Sheet3

  • Seiri = SortingDealing with papersHow to reduce papers on your table ?1. Make a single pile of papers2. Go through them and sort in following categoriesa) Immediate actionb) Low priorityc) Pendingd) Reading materiale) For information

  • Seiri = SortingDealing with papersHow to reduce papers on your table ?4 D Principle

    DODELEGATEDELAYDUMP

  • SEITION = Systematic Arrangement Meaning 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 placeSuccess- Time saved in searching (30 sec to locate an item)Indicator - Time saved in material handling

  • SEITION = Systematic ArrangementIn short, SEITION means PEEP

    Place for Everything & Everything in its place

  • Seiton = Systematic ArrangementHow to achieve Systematic Arrangement ?

    Decide where things belong

    Decide how things should be put away

    Obey the Put away rules

  • Seiton = Systematic ArrangementHow to achieve Systematic Arrangement ? Decide where things belong - Standardize Nomenclature - Determine an analytical method of storage Decide how things should be put away - Name & locations to everything. Label both item and location - Store material functionally - Prevent mistakes with coding by shapes & color

    contd..

  • Seiton = Systematic ArrangementHow to achieve Systematic Arrangement ? Decide how things should be put away - Follow first in first out rule - If two identical items are to be located, then store them separately, color code them.

    Obey the rules - Put the things back to their location after their use

  • Seiton = Systematic ArrangementUSE :

    1 ) Signboards

    2) Color codes

    3) Outline markings

    4) Labels

  • Seiton = Systematic ArrangementFunctionalStorage

  • Seiton = Systematic ArrangementUsageFrequency Store frequently used material near the workplace and less frequently at some distanceWeight &Shape of theMaterial Heavy material should be stored at lower levels/layers Place directly on the material handling device for ease of handlingFunctional Storage

  • Seiton = Systematic ArrangementCategory Same category of material may be stored in one location. Eg. Fasteners, Seals , resistorsOperationWise All items required for an operation may be stored in one location. Eg. Allen key, spanner etc hand tools required for setting m/cFunctional Storage

  • Seiton = Systematic Arrangement Outlining 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

  • Seiton = Systematic Arrangement Wires and Ducts - Color 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