House Keeping5S

Jayant Karandikar

Principle Consultant Qimpro

5S BASIC TRAINING

What is 5S and why do we want to do it?

What is 5S and why do we want to do it?

5S is short for: Sort, Set in Order, Shine, Standardize and Sustain

5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems).

These are foundational to Kaizen (continuous improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts.

5S is one of the activities that will help ensure our company’s survival.

5S

1. Sort Seiri- All unneeded tools, parts and supplies are removed from the area

2. Set in Order Seiton- A place for everything and everything is in its place 3. Shine Seiso- The area is cleaned as the work is performed 4. Standardize Seiketsu- Cleaning and identification methods are consistently applied 5. Sustain Shitsuke- 5S is a habit and is continually improved Also - Work areas are safe and free of hazardous or

dangerous conditions

Some New Words

Red Tag-Process for tagging, removing and disposing of items not needed in the work area.

Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes

Some Japanese words you need to know: Kaizen-(pronounced “ki zen”) - improvement

Kaizen Event and 5S Event-Planned improvements to a

specific area or process (usually take 3 to 5 days).

5S Events focus on making 5S improvements.

Muda-(pronounced “moo da”) - waste

Gemba-(pronounced “gim ba”) - workplace

New Words - Continued

Kanban-(pronounced “kon bon”) - Pull type inventory control system. Items are only produced to meet customer needs. The request to produce more is signaled from an upstream operation and/or customer orders.

Value Stream Map - A diagram of all processes needed to make and deliver the product to the customer.

OTHER PROBLEM SOLVING TOOLS

TOC-Short for Theory of Constraints. Problem solving and constraint management methods. Use the 5 Step form of TOC to solve problems that you will encounter in your continuous improvement efforts.

The current situation

Space is crowded with parts and tools Unneeded items are stacked between workers Excess inventory on the floor Excess items and machines make it difficult to

improve process flow Equipment is dirty and a collection point for

miscellaneous materials Needed equipment such as tools are difficult to

find

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

Dispositioning Items

Ideas for using 5S Tags and dispositioning items during the Sort phase:

• . • .

– .

No 5S TagUsed at least once every two days. Do not remove the item from its place of use

5S Tag, Type AUsed about once a week. Remove it from the direct work area but store it close to the work area.

5S Tag, Type BUsed once a month. Store it somewhere accessible in the facility

5S Tag, Type CUsed once a year or less frequently. Consider storing it outside or moving it off-site

5S Tag, Type DNo longer needed. Remove: sell, return, donate, or discard.

5S Examples - Shine

3. Shine - The area is cleaned as the work is performed (best) and\or there is a routine to keep the work area clean.

5S Examples - Standardize

4. Standardize - Cleaning and identification methods are consistently applied

Departments have weekly 5S tours

Every job has duties that use Sort, Set in Order and Shine

We all have common duties to do our part to keep all areas of the plant in shape - breakroom, restrooms, locker area, parking lot, etc

5S Examples - Sustain

5. Sustain - 5S is a habit and is continually improved

5S is a simple concept with powerful results.

You will get additional information on 5S so that you will be well equipped.

Our experience is that the more we do 5S the better the work environment becomes: cleaner, safer, more organized, the work is easier, less confusion and less stress.

Use the 5S (work\home\play) - The more you use it the easier it becomes and life just gets better and better.

The Good, Bad and the Ugly

First the Bad and the Ugly - Life Without 5S

The Good

What is Waste (Muda)? Some of the main forms of waste are:

Overproduction

Waiting for materials, machines, or instruction

Transportation or movement

Excessive inventory

Inefficient machine processing and/or operation

Producing defects

Part or line changeover or machine setup

Inadequate housekeeping

Miscommunication or inadequate instruction

Improvement (Kaizen) Principles

Get rid of all old (false) assumptions. Don't look for excuses, look for ways to make it happen . . Don't worry about being perfect - even if you only get it half right “start NOW”! It does not cost money to do KAIZEN. If something is wrong “Fix it NOW”. Good ideas flow when the going gets tough. Ask "WHY" five times - get to the root cause. Look for wisdom from Ten people rather than one. Never stop doing KAIZEN.

Summary

5-S is for you.

Clean-up and organize your work area every day so that each new day is easier and safer than the day before

Share your input with your leaders so that the tools you need will be available to you, increasing your efficiency.

Volunteer to help with the 5S tours and 5S events.

Take a good look around...Imagine zero waste/zero confusion!

.

The 5S Flow Plan

Plan a course of action. Educate the work group. Assess the work are Initiate the 5S's. Measure the results. Maintain 5S activities. Deploy to other areas.

THE 5S's AND THE PLAN-DO-CHECK-ACT MODEL

P

DC

A

1. Plan a course of action

2. Educate work group3. Evaluate work area

5. Measure the results

6. Maintain 5S activity

4. Initiate 5S

Activity 1. Plan a Course of Action Step 1. Organize 5S-Related Materials Step 2. Coordinate Internal Activities and Services

Needed From Other Departments Step 3. Establish a Schedule Step 4. Selecting the 5S Team Step 5. Establish Visible Ways to Communicate 5S

Activities Step 6. Present Plan to Upper Management & Define

Individual Responsibilities Step 7. Review Your Plan

Activity 2. Educate the Work Group Step 1. Refer to Your Implementation Plan to Decide

When to Schedule Instruction Step 2. Schedule Work Groups for Instruction Step 3. Review the Material and Rehearse the

Presentation Step 4. Present the Lesson Plan

Activity 3. Evaluate the Work Area Step 1. Use the Following Tools to Aid Evaluation Step 2. Coordinate Area and Section Boundaries Step 3. Divide the Work Area Into Sections Step 4. Conduct 5S Appraisals

5S Assessment

Activity 4. Initiate the 5S's

Step 1. Sorting Step 2. Simplifying Access Step 3. Sweeping Step 4. Standardizing Step 5. Self-Discipline

Activity 5. Measuring Results

Step 1. Conduct a Post-Implementation Assessment

Step 2. Analyze Results of the Post-Implementation Assessment

Step 3. Benchmarking

Activity 6. Maintaining 5S Activities (Making 5S a Habit) Step 1. Setting Goals Step 2. Establishing Sops (Standard

Operating Procedures) Step 3. Adhering to the 5S Process

Schedule

Conclusion

Plan a course of action. Educate the work group. Evaluate work area. Initiate the 5S's. Measuring results. Maintaining 5S activities.