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Overview of 5S

WELCOME

Prashant RaneSafety, Health & Environment

26 May 2010

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5S Principles

Elimination of all types of wasteElimination of all types of waste Every body is involved, Every body is involved,

Team work Team work Attack root causeAttack root cause Continual improvement is Continual improvement is

possiblepossible Mind set change, culture Mind set change, culture

buildingbuilding

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What are 5S ?

• 5S are five Japanese words 5S are five Japanese words beginning with Sbeginning with S

• Involvement programmeInvolvement programme• Participation programmeParticipation programme• Culture building pathCulture building path• System for continual improvement System for continual improvement

of mind set of employeesof mind set of employees

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5S is foundation for visual factory

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What are the 5 S´s ?

SEIRI SHITSUKESEIKETSUSEISOSEITON

Time

Develo

pm

en

t

SEIRI Sorting / Organise SEITON Neatness SEISO Cleaning SEIKETSU Standardisation SHITSUKE Self Discipline

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Objectives

1S: Release the space2S: Minimize searching and access

time3S: Zero Leakage

: Zero Spillage: Make easy to clean and inspect: Zero Accident: Zero Breakdown: Zero Abnormality..

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Objectives continued..

4S : Zero rework : Zero internal rejection

: Zero external rejection : Zero customer complaints : Zero variance on all targets and commitments

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Objectives continued..

5S : Zero violations of rules : Zero violations of procedures and policies

: Zero reminders

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Objectives continued..

Improve housekeepingImprove housekeeping Make every individualMake every individual responsible for housekeepingresponsible for housekeeping Beautify by simple meansBeautify by simple means Productivity improvement by Productivity improvement by saving time, space etc.saving time, space etc.

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1S : SEIRI = 1S : SEIRI = SortingSorting1S : SEIRI = 1S : SEIRI = SortingSorting

Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items

Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items

Activity Establish a criteria for eliminating unwanted itemsEliminate unwanted items either by disposing

them or by relocating them.

Success Area saved or released as a percentage of space

Indicator available

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2S : SEITION = 2S : SEITION = Systematic Systematic ArrangementArrangement

2S : SEITION = 2S : SEITION = Systematic Systematic ArrangementArrangement

Meaning To determine type of storage and layout that will ensure easy accessibility for everyone .

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 place

Success - Time saved in searching and access

Indicator - Time saved in material handling

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SEITION = SEITION = Systematic ArrangementSystematic ArrangementSEITION = SEITION = Systematic ArrangementSystematic Arrangement

• Easy to identify

• Easy to Locate

• Easy to Pickup and access

• Easy to keep it back

• Easy to Inspect

• Easy to read

• Easy to instruct

• Easy to identify

• Easy to Locate

• Easy to Pickup and access

• Easy to keep it back

• Easy to Inspect

• Easy to read

• Easy to instruct

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OrganizationOrganization

Frequency of use Storage Method

*Things you have not used in the past one year

Throw them out

*Things you have used once in the last 6-12 months

Store at distance OR Keep in store

LOW

*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 zoneAVER

AG

E

HIGH *Things used once a week Store near the workplace

*Things used daily or hourly Store near the workplace

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3S: SEISO = 3S: SEISO = Cleaning Cleaning 3S: SEISO = 3S: SEISO = Cleaning Cleaning

Meaning Cleaning trash, filth, dust and other foreign

matter. Cleaning as a form of Inspection

Meaning Cleaning trash, filth, dust and other foreign

matter. Cleaning as a form of Inspection

Activity - Keep workplace spotlessly clean- Inspection while cleaning- Finding minor problems with cleaning inspection

Success - Reduction in spillage, leakages, down time

Indicator - Reduction in no. of accidents

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SEISO = SEISO = Cleaning Cleaning SEISO = SEISO = Cleaning Cleaning

• Organise major initial cleaning• Identify the Leakages and put tags• Identify the spots difficult to clean• Implement Projects to make

cleaning easy• Team involvement in projects

• Organise major initial cleaning• Identify the Leakages and put tags• Identify the spots difficult to clean• Implement Projects to make

cleaning easy• Team involvement in projects

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SEISO = SEISO = Cleaning Cleaning SEISO = SEISO = Cleaning Cleaning

• Develop cleaning checklist• Train for doing root cause

analysis

• Develop cleaning checklist• Train for doing root cause

analysis

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Seiso = Cleaning and InspectionSeiso = Cleaning and Inspection

5-10 Minutes Every day for cleaning5-10 Minutes Every day for cleaning• Devote 5 minutes everyday for Devote 5 minutes everyday for cleaning your work areacleaning your work area• Participation of everyone Participation of everyone is requiredis required• Attack hard to clean places Attack hard to clean places regularlyregularly

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Seiso = Cleaning and InspectionSeiso = Cleaning and Inspection

Create a checklist for initial cleaning Where ?How ? (Equipment, Material, ...)How often ? (daily, weekly, ...)

Create a checklist for initial cleaning Where ?How ? (Equipment, Material, ...)How often ? (daily, weekly, ...)

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SEIKETSU = SEIKETSU = StandardizationStandardizationSEIKETSU = SEIKETSU = StandardizationStandardization

Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure and standards)

Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure and standards)

Activity - Innovative visual management- Colour coding- Early detection of problem and early

actionSuccess Improvement in 1S, 2S and 3S level

Indicator Zero Rejections, Variance on targets

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SEIKETSU = SEIKETSU = StandardizationStandardizationSEIKETSU = SEIKETSU = StandardizationStandardization

• Seiketsu is result of first 3S implementation

• Systematic training on problem solving is must to all team members

• Seiketsu is result of first 3S implementation

• Systematic training on problem solving is must to all team members

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SHITSUKE = SHITSUKE = Self DisciplineSelf DisciplineSHITSUKE = SHITSUKE = Self DisciplineSelf Discipline

Meaning Every one sticks to the rule and makes it a habit

Meaning Every one sticks to the rule and makes it a habit

Activity - Participation of everyone in developing good habits

- Regular audits and aiming for higher level

Success High employee morale

Indicator Involvement of all people Growth of the organisation

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SHITSUKE = SHITSUKE = Self DisciplineSelf DisciplineSHITSUKE = SHITSUKE = Self DisciplineSelf Discipline

• Develop the rules, procedures, practices, standards• Train all the employees to understand and use• No follow up is required• No. chasing is required• No Reminding is required• No violations of norms or discipline• Employee is proud of his role and activity

• Develop the rules, procedures, practices, standards• Train all the employees to understand and use• No follow up is required• No. chasing is required• No Reminding is required• No violations of norms or discipline• Employee is proud of his role and activity

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SHITSUKE = SHITSUKE = Self DisciplineSelf DisciplineSHITSUKE = SHITSUKE = Self DisciplineSelf Discipline

Activities :

5S Training

5S Month, exhibitions

Posters , Literature etc.

Periodic audits of the level of the 5S

Worst photo contest

Presentations by each team

Activities :

5S Training

5S Month, exhibitions

Posters , Literature etc.

Periodic audits of the level of the 5S

Worst photo contest

Presentations by each team

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Shitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self Discipline

We need everyone to maintain 5SWe need everyone to maintain 5Sguidelines.guidelines.

To maintain DISCIPLINE, we needTo maintain DISCIPLINE, we needto practice and repeat until itto practice and repeat until itbecomes a way of life.becomes a way of life.

Discipline is the Core of 5SDiscipline is the Core of 5S

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Shitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self Discipline

Discipline means making a steadyDiscipline means making a steadyhabit of properly maintaining habit of properly maintaining correct procedurecorrect procedure.

Time and effort involved inTime and effort involved inestablishing proper arrangementestablishing proper arrangementand orderliness will be in vain if and orderliness will be in vain if we do not have discipline towe do not have discipline tomaintain it.maintain it.

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