5S Training:Improving your workplace improves you

By – AJAY & SHUBHAM

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5S BASIC TRAINING

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

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Little to 5S

5S is short for:SortSet in Order (Straight)ShineStandardizeSustain

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

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

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

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Just so you know Better

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For Better meaning of 5 -> S

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

2. Set in Order - A place for everything and everything isin its place

3. Shine - The area is cleaned as the work is performed4. Standardize - Cleaning and identification methods are

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

Also - Work areas are safe and free of hazardous ordangerous conditions

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5S – what should we do

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5S – SORT - (Retain or remove)

1. Keep only what is needed in your working area2. Sort Needed items based on their frequency of use:

1) Daily – put them to your easily accessible place2) Weekly – Put them close to you3) Monthly – Put them away from your work place

3. Determine and use only proper quantity of use(no excess no short)

4. Eliminate or remove any unneeded item from your workplace to the place where it may be needed or to Scrap. (Use red sticker technique to identify unneeded items)

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5S – SORT - Red Tag - Sample

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5S - SORT – 12 Steps to plan this activity

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5S – SORT – Checklist for Warehouse

Materials, parts or components-Are materials moved in a timely manner?

Machines and other equipment-Are there any unused machines or other equipment around?

Visual control-Are all waste materials in the correct skips?Containers-Is customer packaging stored safely & in correct locations?Is unused equipment and machinery eliminated from the area?Is the floor clear of all tools, spare parts and materials?Are the floors in 'common areas' free of trash and debris?Is obsolete inventory and raw material eliminated from the area like below the table?

Is the work in process organized so as to reduce travel time and other forms of waste?

Is the work in process inventory reduced to the least possible amount ?

Are aisles, doorways, electrical panels, and fire extinguishers free from material and blockages   ?

Are tripping hazards and obstructions eliminated from the area?Have we removed unintentionally dropped and stuck barcoded from the ground?

Are the record files being kept in Almirah?

Is all scrap has its defined location?

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5S – STRAIGHTEN – Everything in place

1. “STOP”, Proceed only if SORT has been accomplished2. A place should be assigned for everything and everything

should be placed to its assigned place after use.3. Even if someone is not familiar with the are, should be

able to find something required4. Every place of use should be properly labelled

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5S – STRAIGHTEN – 3 steps for the activity

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5S – STRAIGHTEN - Checklist

Location indicators-Are Sub-Con locations clearly marked?Item Indicators-Are shelves clearly marked with location?Quantity Indicators-Are Finished Goods stacked to correct No. of boxes?MHE Parking-Are all unused trucks parked in the designated area?Material storage-Is stock rotation ( FIFO ) being adhered to?Are work areas, storage areas and equipment surroundings clearly labeled, marked, and/or footprinted if necessaryAre storage places for tools and equipment designated and markedAre storage places for work in process designated and markedIs machinery, storage equipment and columns identified and numberedAre all pipes, controls and gauges identified and labeled to show function or purpose                       Are team boards/bulletin boards current and in good order

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5S – SHINE – Look like and work like brand new

1. Clean with purpose and always maintain a clean and shiny work place. (Be attentive towards details)

2. Even if Items are sorted and put in necessary place, so then when needed they can be easily pulled out. There will be no use if the product is of no use.

3. It is important to give value to the product and maintain the same for as long as possible

4. Don’t Forget – It obviously also means to sweep floors, WIP of machinery and generally making sure that everything in your workplace stays clean.

5. It’s a daily activity which combines cleaning and maintenance

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5S – SHINE – Steps to follow

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5S – SHINE - Checklist

Floors & gangways-Are floors, exits & entrances kept clear, clean and free of waste, water or oil?MHE-Are MHE kept clean & free of rubbish?Work Surfaces-Are work surfaces clean & tidy?Cleaning Responsibilities-Is the person responsible allocating cleaning duties? (Stores Supervisor)Habitual cleanliness-Is the set standard ( photo ) being maintained?Are recycling bins located as necessary with trash and recycling being cotrolled in the area5S holding and dispo areas are well maintained Are slot locations free of empty pallets and trashAre machines clean, well kept and in good repairAre slot locations in pick ready conditionAre slot locations free of hanging shrink wrap and/or bandingFloors and equipment in the area are free of dirt / grease/ or fluids

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5S – STANDARDIZE – Combination of 1st 3

1. It’s the result, If all 3 are strictly followed then result can be called as your standard.

2. It also means that if you have worked on 5 packaging stations. After 1st 3 steps all 5 should look alike.

3. Responsibility should be clearly defined for 1st 3 steps

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5S – STANDARDIZE – Steps to follow

Provide standard procedures and checklists Document the standards Incorporate SORT, STRAIGHTEN and SHINE in

daily activities standardize for multiple processes.

Make standards visual and obvious Make the standards easily understandable for

every co-workers Prevent setbacks to original states and future

problems from occurring

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5S – STANDARDIZE - Checklist

Concerns sheets-Are concerns regularly being generated?Concerns-Are concerns regularly being acted upon?Operation standards-Are Operation Standards written, clear and actively used? (Ask an Operator)Check Sheets-Have checks been carried out & documentation completed?Are shine maps available and employees aware of responsibilitiesIs standard work in place, including quality checks, and in use at all work stationsAre bins and parts properly identified and labeledAre supplies labeled and in their placeAre footprinted and labeled areas adhered toAre visual safety signs and floor markings used to identify hazards in the area

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5S – SUSTAIN – Make it you habit

1. Maintain and review standards.2. 4S have set a new way to operate, make this new way you

SOP.3. Making it a habit to follow all the defined procedures4. Most difficult – 90% join gym, only 2% continue.5. Output is directly proportional to the efforts put in this

section

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5S – SUSTAIN – Steps to Sustain

Determine 5S level of achievement Conduct audits on workplaces and provide

feedbacks Analyse results by routine checks Chart the audit scores on visual display board Measure progress and further plan for

continuous improvement

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5S – SUSTAIN - Checklist

Training-Is everyone adequately trained in 5S procedures? (Ask what 5S is)Parts-Are parts being stored correctly?Timed Deliveries-Are times being adhered to?Cleaning routine-Is cleaning routine present & are all tools & materials available?Hourly Monitor-Are supplier delivery times adhered to?Are all start-up safety checks carried out and documentedIs everyone within the area wearing proper personal protective equipmentAre unused tools, equipment, raw materials and work properly storedAre emergency plans, labels and equipment visible and properly stored in areaAre corrective actions from 5S audit identified and adhered toAre employees receving weekly feedback on their 5S effortsIs there evidence of the 5S daily checklist being used and updated 5S audit scores on the teamboard

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Basic suggestions in Kaizen Principle

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.

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Direct Visual Difference – Before and After

Have you played find 10 differences ????

Here you can and sothis is an activity for you

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The Good, Bad and the Ugly

First the Bad and the Ugly - Life Without 5S

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The Good, Bad and the Ugly - dobara

And then the GOOD - Life With 5S

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See it live

Week of ___/____/____ Assessor: __________________ Area or Zone:________________________

For each “S”, Circle the block which comes closest to describing the area being assessed.

5 Points World Class

4 Points Very Good

3 Points Minimum Acceptable

2 Points Marginal

1 Point Unacceptable

0 Points Poor

Separate/Sort Every item in the area is needed and up-to-date. Consider: - Supplies - Tools - Equipment - Furniture - Documents - Bulletin board postings

Minimal clutter, but a small amount of unneeded supplies, tools, equipment, furniture, documents or general items.

The area has some clutter and unneeded items. Some items stored on top of cabinets. Some needed items are not available or on order.

More clutter and unnecessary equipment. There is no unneeded furniture or equipment, but desks, shelves and cabinets have excess items.

Generally cluttered. Quite a few unnecessary items either on benches, desks, shelves or cabinets. Some unneeded furniture and equipment. Items stored on floor.

Station is cluttered/unsafe. Many unnecessary items everywhere. Much unneeded furniture, & equipment. Emergency equipment blocked.

Straighten Area very well organized. Excellent visual controls are in place. There is a designated or labeled location for all items. Locations are convenient and items are stored properly. Equipment and aisles have designated markings

Area well organized. Most moveable items have a designated location. Although not perfect, most locations are good, and items are stored properly. Equipment, tooling & related supplies are co-located & orderly. Many visual controls are in place. Aisles are neat & clear.

Area well organized. With the exception of a few problems, most items have a designated appropriate location, and most tools, documents & supplies are stored properly. All aisles are marked, but some moveable equipment is not. Many visual controls are in place.

Area moderately organized. Many key items have a designated location, but some do not, and some items are improperly stored. Equipment and aisles may not be clearly marked. Although some visual controls are in place, many more could be added.

Inadequate organization. Many key items have no designated location. Shelves and drawers are poorly labeled. Aisles or equipment markings are not clear or straight. Very few visual controls or instructions are evident. Safety equipment is not designated.

Poor organization. Little indication for a designated place for anything. Items improperly stored on the floor and benches. Trip hazards. Furniture and tools located far from where needed. No current visual controls, signs or labels.

Scrub/Shine Everything in the area is in “like new” condition. Oil socks are not required. No dust or dirt anywhere. Floors shine.

Everything in the area is clean and functional. Oil socks are not needed. Floors are clean, and baskets are emptied daily.

Most items in the area are clean and functional. Oil socks are neat. Some equipment malfunction or needs painting. Floors are pretty clean and baskets are emptied daily.

There is some clutter. Some items are not clean and/or swept. Some oil leakage in pan. Floors and/or waste containers are marginal.

Area needs to be picked up. Items have not been cleaned in some time. Significant oil leakage. Floor is dirty and/or waste containers are full.

Area is very dirty. Furniture, equipment, shelves, fixtures, and tools area coated with dirt and/or oil. Possible health and safety hazards exist, such as trip hazards, or obstructed emergency items or exits.

Standardize A 5S checklist is posted in the area and it is clearly followed everyday. All required PMs have been performed. All metrics and charts in the area are current. It is clear that follow-up actions to identified problems have been done.

A 5S checklist is posted and seems to be followed. All required PMs have been performed. All metrics and charts in the area are current. It is clear that follow-up actions to identified problems have been done.

Although a 5S checklist is not posted, it is available. All required PMs have been performed. All metrics and charts in the area are current. It is somewhat clear that follow-up actions to identified problems have been done.

Although a 5S checklist is not posted, it is available. All required PMs have been performed. Metrics and charts in the area are not current. It is unclear that follow-up actions to identified problems have been done.

There is no evidence that a 5S checklist exists for the area. All required PMs have been performed. Metrics and charts in the area are not current.

There is no evidence that a 5S Checklist exists for the area. PM log is not up to date. Metrics and charts in the area are not current.

Sustain There is a clearly documented and followed system to maintain 5S.

There is a system in the area and strong interest in maintaining 5S.

There is a system in the area and moderate interest in maintaining 5S.

There is a system in the area and spotty interest in maintaining 5S.

There is no system in the area and little interest in maintaining 5S.

There is no system or commitment within the organization to sustaining 5S.

# of 5’s circled: ____ X 5 = ______ Opportunities for Improvement: Who When # of 4’s circled: ____ X 4 = ______ # of 3’s circled: ____ X 3 = ______ # of 2’s circled: ____ X 2 = ______ # of 1’s circled: ______ Total: ______ 5 =

5S Rating

5S Manufacturing Evaluation

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What you get with 5S – Straight Advantages

1. NEAT & CLEAN WORKPLACE2. PRODUCT DIVERSIFICATION3. SMOOTH WORKING4. NO OBSTRUCTION5. SAFETY INCREASES6. PRODUCTIVITY IMPROVES7. QUALITY IMPROVES7. WASTAGE DECREASE8. MACHINE MAINTENANCE9. VISUAL CONTROL SYSTEM10. EMPLOYEES MOTIVATED11. WORKSTATIONS BECOME SPACIOUS12. IN THE END REDUCED COST

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Activity

1. Take the PPT2. Read -> Read again3. Plan your schedule to perform each activity under everyone’s

supervision4. Convert this PPT to your warehouse Report5. Replace the before and after images in the PPT with your

warehouses images6. Right down what extra inputs were put apart from the steps

mentioned – Others will follow and you will be rewarded7. Show us the change you saw apart from obvious8. Start form Monday9. Make the reporting a weekly report

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