training- 5s
TRANSCRIPT
Picture -1 Picture -2
Look at these two pictures ?
Which Picture shows Good Workplace ?
Which Picture shows Clean Workplace?
Which Picture shows Organized Workplace?
Which Picture shows Good Arrangement?
Which Picture shows unneeded items?
Which Picture shows, less time require to find things?
Which Picture shows, tidy workplace?
Definitely Picture - 2.
But How it can be achieved?
This is achieved by a method,
to organize the Workplace,
Called as 5S.
What is 5S ?
5S is a Philosophy and a way of organizingand managing the workspace and workflow.
The intent of 5S is to improve efficiency by eliminating waste, improving flow and
reducing process unevenness.
It uses five Japanese Words, which are converted and translated
Into English, start with letter S.
5S sometimes incorrectly referred asHousekeeping or Cleaning,
whereas
It is more than Housekeeping/Cleaning
5 S
towards
ideal
shop floor
Seiri – 1S
Seiton – 2S
Seiso – 3S
Seiketsu – 4S
Shitsuke – 5S
5S First s – Sort known as Seiri
5 Stowards
ideal
shop floor
– Remove all items from the workplace that are not needed for current operations.
When it is needed
In the amount needed
– When in doubt, throw it out!
What is needed
1. Discard what is unneeded
This involves identifying unneeded from stocks,around machines, from cupboards, documents, from workstation, from warehouse and storages, from office.
2. Classify the needed things
This involves organising a classification of objects using labels identifying their frequency of use: these labels are to be positioned when the initial cleaning is taking place.
5 Stowards
ideal
shop floor
5S Second s – Set in Order known as Seiton
5 S
Organize
Arrange needed items so that they are– Easy to use – Easy to find– Easy to put away
Do not place heavy objects high up.
Easy to pick up,easy to put back,
easy to do.Place the most usedobjects at a height
between theshoulder and the
elbow
Make shelves appropriate to
the size and weight that will
be placed there.
CorrectIncorrect
Define how to order the objects
Define how to order the objects
equipment on wheels: define the position by color and write the name of the vehicle.
as a general rule, indicate the position of everything that has to be moved, so as to be able to replace it more easily.
Mark the position of the objects (marks, labels, ......)
Do not leave containers directly on the floor
use a platform: the parts will not be soiled, and corrosion and knocks can be avoided.
Define how to order the objects
parts box
Platform
Access difficult
Access easy
Avoid placing things too far back as it makes them difficult to reach.
Plan strategies to make organisation easy
Marking makes it possible to replace documents exactly in order
Badly placed
Well placed
Define how to order the objects
This functional order must be organised with the help of the operators, who can make proposals to the 5S work group.
This will ensure:
greater safety
improved quality of parts made
no time wasting
Indicate the part names
Heightlimit
On the platform
Area line
Indicate the quantity and the name of the container
Mark the area according to
the size of the containers
Define how to arrange the objects
Plan a clear system for positioning giving maximum information in a minimum of time
Define how to order the objects
Correct
Incorrect
Draw very legible marks in the installations to make inspection easier.
5S Third s – Clean -(Spic and Span) known as Seiso
5 Stowards
ideal
shop floor
Clean everything
– Sweep floors
– Wipe machinery and equipment
– Paint and repair
– Remove cob webs
– Washrooms
– Under the machine/Behind the machine/Inside of machine
– Oil spillage on the floor, from the machine
– Waste Bins
– Material Bins
– Office equipments and accessories like Computers, Desk, chair etc
– Building Structural Parts like Columns, Beams.
– Pipelines (Clean and Paint)
– Repair and maintain machines, equipments, furniture, lights, floors,
stairs, windows, doors, glass, signages and other structures etc.
- Maintain garden
Rag
Brush
Bleach
Sweeping brush
Vacuum cleaner
Paint
Paint brush
Other equipment
Spic and Span
Use Cleaning equipments for cleaning
5S Four s – Keep the work place clean every time (Standardize) known as Seiketsu
5 Stowards
ideal
shop floor
Prevents problems
Standardized Cleanup
Establishing a method to maintain the first three pillars
Everyone’s responsibility
Define the operational cleaning procedures. (SOP’s & WI for cleaning)
Define the cleaning plans and post them where they can easily be seen on the workstation.
These plans must define:
the place to be cleaned
the means to be used
the time to be devoted to it
how often the cleaning have to be carried out
who has to clean
Standardized Cleanup
5S Fifth s - Maintain – Self Decipline known as Shitsuke
5 Stowards
ideal
shop floor
Discipline
– Making order and cleanliness a habit
– Establish a culture of clean
– Get used to applying the above 4S
– Audit and Evaluate the standard
SORT (Organization)
Clearly distinguishneeded items from
unneeded items and eliminate
the latter
Keep needed itemsin the correct
place to allow foreasy & quick
retrieval
SET IN ORDER (Orderliness)
This is the condition we
support whenwe maintain the
first three pillars
STANDARDIZE (Standardized
Cleanup)
workshopswept and
clean
Keep the
SHINE (Cleanliness)
SUSTAIN (Discipline)
Make a habit of maintaining established procedures
Respect the rules we have imposed on ourselves:
by leaving no object outside the storage or unloading areas
by preserving delimited areas
by respecting indications
by cleaning the work area as per standard
Dangerous area
Get used to applying the 5S
Resistance to Implementing 5S
What are the reasons for resisting 5s implementation?
Resistance to Implementing 5S
What’s 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.
We’re too busy for 5s.
We did 5s years ago.
What are the reasons for resisting 5s implementation?
Benefits of Implementing 5S
What are some benefits of implementing 5s?
Benefits of Implementing 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.
Implementing 5S
Implement SORT with a red tag campaign
Place red tags on items that need evaluation
Red-tagging is a method for identifying potentially unneeded items, evaluating their usefulness, and dealing with them appropriately.
Ask– Is this item needed?– If so, is it needed in this quantity?– If it is needed, does it need to be located here?
Implement SORT with a red tag campaign
Assign one area in plant / deptt for keeping unneeded material found from 1S activity
Keep the material in that area for predetermined period before discard them.
Discard the material if have no use.
Steps for Implementing the SET IN ORDER
Decide the location of items that eliminate waste– Principles of motion economy– 5S map
Tools– Signboards– Paint paths and areas– Color-coding– Outlining
Label locations– Area, specific placement, and amount
Once the best locations have been decided, you must identify locations so ANYONE will know:– What goes where
– How many of each item go in each location How?
– Outlining Strategy
– Signboard Strategy
– Painting Strategy
– “After” 5S Map
– Color-coding Strategy
Label Locations (SET IN ORDER)
Organize items so they are – easy to use – easy to find – easy to put away
Outlining Strategy (SET IN ORDER)
Sign Boards (SET IN ORDER)
Signboards have: Location
indicators
Amount indicators
Item indicators
Painting Strategy (SET IN ORDER)
Painting identifies locations on floors and walkways.
Place markers for work tables
Place markers for operators
Cart storage locations Pallet storage locations
Implement SHINE with careful planning
1. Determine targets (Identify all areas require cleaning)
Warehouse items (Storage Racks, Bins)
Equipments (Machines)
Space (Floor)
2. Determine assignments and schedule– Develop 5S Map of area/machine showing all equipments
and 5S Schedule for Sorting, Setting and Shining
3. Determine methods– Identify tools required for cleaning like brush, rag, air, vaccum
cleaner.– Develop the procedures for cleaning ie. How to clean
Implement SHINE with careful planning
4. Prepare cleaning tools
- Provide the Standardize storage for cleaning tools
- Inspect the cleaning tools regularly using Checklists
5. Shine
- Clean the machine, equipment, workarea by following the cleaning procedures.
Implementing STANDARDIZE
Decide who is responsible for which activities for maintaining 3S conditions
Integrate 3S maintenance into regular work duties
Check to see how well 3S conditions are being maintained
Establishing a method to maintain the first three pillars
Set up a schedule for cleaning (for workplace, office and beyond workplace)
Schedule should contain 4W+1H - What to clean - Where to clean - Whom to clean - When to clean - How to clean Schedule should be followed and checksheet filled daily
Implementing STANDARDIZE
Cleaning Schedule - Machine ______________
What Where Whom When How Remarks
Machine inside Fixture Operator Daily Using Brush
Machine outside On Top Operator Weekly Using Cloth
Machine Pipelines Upto 5 ft from m/c
Housekeeping
Weekly Using Cloth
Implementing STANDARDIZE
• Develop standard for practicing 5S daily
Implementing SUSTAIN
Make cleanliness a habit
Create conditions which will sustain your efforts
– Schedule time to maintain order and cleanliness
– Committed support and recognition from management –
– 5S Slogans– 5S Posters– 5S Maps– 5S Newsletters– 5S Tours– 5S Audits– 5S Storyboards
Implementing SUSTAIN
• Prepare Audit Checksheet
• Audit the Work Area daily • Audit should be done by CFT or Supervisor or Operator • Evaluate the audit findings
• Plan for correcting the problems
• Take approval for improvement
• Implement the improvement
• Sustain the improvements
Examples of 5S
5S of Shopfloor5S of Tools
5S of Desk
5S of Documents
5S of Beyond Workplace
5S of “5S Board”
5S of Tools
5S of Tools
Success with 5S
Before After
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Thank you!