5s ppt

Training Session

5 Son

Part 1 - What is 5 S&

Part 2 - How to Implement 5 S

Part 1 - What is 5 S

Now, we will see !

QUALITYQUALITY

SAFETYSAFETY

EFFICIENCYEFFICIENCY

CONTROLCONTROL

Customer Satisfaction

Employee Satisfaction

Equipment

Material

Jigs/Tools

Method

Workers

Products

Timeliness

Maintains

Ensure Max. Utilization

UpkeepsImproves

Motivates

Ensures Good

Promotes

Impact of 5 S at the Workplace

INDIA

U. S. A.

JAPAN

1950 1960 1970 1980

•Seiri - Sorting

•Seiton - Systematic Arrangement

•Seiso - Cleaning

•Seiketsu - Standardization

•Shitsuke - Training & Discipline

What are the 5 S?

What is

We Will See First ….!

SEIRI(SORTING)

Seiri - Sorting

SEIRI - SORTING /REORGANISATION

To clearly devide objects in to two groups

•Those items that are necessary.

•And Those items that are not necessary.

•To get rid of the unnecessary and to keep the necessary.

Seiri - Sorting

WHAT IS UNNECESSARY

• Item is not needed.

•Item is needed however, quantity in stock is more than what is needed for consumption in near future

•Contingency Parts : Critically decide the quantity of contingency parts to be retained and criteria for such parts.

Seiri - Sorting OrganisationFrequency of use Storage Method•Things you have not used Throw them out in the last one year.•Things you have used once Store at distance OR in the last 6-12 months. Keep in store•Things you have used only Store it in central once in the last 2-6 months. place in your zone.•Things used more than once Store it in the central a month. place in your zone•Things used once a week Store near the

workplace.Things used daily or hourly Store near the

workplace.

LOW

AVER

AGE

HIGH

Seiri - Sorting Organisation

Identifying unnecessary1) Parts and Work in Process (WIP)•Things fallen back behind the machine or rolled under it.•Broken item inside the machine•Things under the rack/platforms.•Extra WIP•Stock of rejected items•Items accumulated over period for rework•Material awaiting disposal decision•Material brought for some trail, still lying even after trail•Small qty of material no longer in use Cont…..


Identifying unnecessary2) Tools, Toolings, Measuring devices•Old jigs, tools not in use lying.•Modified tools, tooling for trial, are lying after trail.•Worn out items like bushes, liners, toggles etc. lying.•Broken tolls, bits etc. may be lying.•Measuring equipment not required for the operation being performed, is lying.

3) Contingency parts•Many times storage place for contingency parts become a last refuge for broken parts, surplus items and things nobody is likely to use. Cont…..


Identifying unnecessary4) Shelves and LockersShelves and lockers tends to collect things that nobody ever uses, like surplus, broken items etc.

5) Passage and Corners :Dust material not required seem to gather in corner.

6) Besides Pillars and under the stairs:These place tends to collect junk, spittoon etc.

7) Walls and Bulletin BoardsOld out dated notices which have lost their relevancePosters or bulletins on wallDust, remain on torn notices, cell tape pieces Cont…..


Identifying unnecessary8) Floor, Pits, PartitionsDefective partsProtection caps, coversPacking materialHardware items, small itemsEven tools,small itemsEven tools, tooloingItems dropped on the floor are never picked

9) Computer Hard Disk•Many unwanted, outdated, temporary files pile up

Cont…..

Seiri - Sorting Dealing with papers

How to reduce papers on your table?

1) Make a single pile of papers

2) Go through them and sort in following categories :a) Immediate actionb) Low priorityc) Pendingd) Reading materiale)For information

Seiri - Sorting Dealing with papers

How to reduce papers on your table?4D principle

DO... DELEGATE….

DELAY….DUMP….

What is

Now,We Will the Second one ...!

SEITON(SYSTEMATIC ARRANGEMENT)

Seiton - Systematic Arrangement

SEITONA Place for Everything And...

Everything in its Place …!


How to achieve Systematic Arrangement?

•Decide where things belong•Decide how things should be put away•Obey the ‘Put away’ rules


How to achieve Systematic Arrangement?• Decide where things belong - Standardize Nomenclature - Determine an analytical method for storage• Decide how things should be put away - Name & location to everything. Label both item and location - Store material functionally - Prevent mistake with coding by shapes & colour

contd….



• 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, colour code them.• Obey the rules - Put the things back to their location after their use



USE:1) Signboard

2) Colour codes

3) Outline marking

4) Labels


Functional Storage


Functional Storage

Usage * Store frequently used material Frequency near the workplace and

less frequently at some distance

Weight & * Heavy material should be storedShape of at lower levels/layersthe Material Place directly on the material

handling device for case of handling


Functional StorageCategory * Same category of material may

be stored in one location. Eg. Allen Screws, Oil Seals

Operation * All items required for an Wise operation may be stored in one

location. Eg. Allen key, spanner etc. hand

tools required for setting m/c


Functional Storage• Outlining and Placement Marks

-Marks boundaries of dept. aisles, Machines-Follows straight line, right angle rule-Nothing shall be kept outside the boundaries

• Stand and shelves-Keep only required number of stands and shelves -Standardize height, size-Provide casters where necessary so that it can be move

Seiton - Systematic ArrangementFunctional Storage• Wires and Ducts - Colour code - When there are multiple connections – bundle the wires, label them and lake 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 tools should be such that it can be put away with one hand - Try to eliminate some hand tools by permanently attaching it to the bolt head

Seiton - Systematic ArrangementFunctional Storage• Blades, Dies other important consumables

- Stores them in the protected place- Maintain these things regularly by applying rust preventive, oiling etc.

• WIP – Work In Process- Designate a place for each component / part- Decide on how much quantity to be stored- Ensure that there is no damage to good part during transit, they do not get rusty and they are not mislabeled.

Seiton - Systematic ArrangementFunctional Storage• Oils

- Reduce number of oils used (Standardize)- Colour code for oil- Safety aspects – fire prevention, pollution, leak, spillage

• Instrumentation & Measuring Devices- Label them, show direction of flow

That is

Now,We Will the Third ...!

SEISO( CLEANING )

Seiso - Cleaning

SEISOClean workplace completely so

that, there is no dust on the floor, machines and equipments …!

Seiso - Cleaning

Activity - Keep workplace spotlessly clean- Inspection while cleaning

- Finding minor problems with cleaning

inspection

Success - Reduction in machine down time

Indicator - Reduction in no. of accidents

Seiso - Cleaning

While cleaning up and getting rid of dirt and unclear items potential defects such as Abrasion, Damage, Loose Parts, Deformities, Leaks, Vibration, Abnormal Sound etc., are revealed and hence Seiso is inspection

Seiso - Cleaning

• Here cleaning means more than just keeping things clean. Cleaning should be viewed as a form of Visual Inspection•Preventive measures should be taken to tackle problems of dust, grim, burrs, leakage etc. Roots cause of the problem should be identified and it should be eliminate

Seiso - Cleaning

5 Minutes Every day for cleaning

•Devote 5 minutes every day for cleaning your work area •Participation of everyone is required •Attack hard to clean places regularly

Seiso - Cleaning

Cleaning - Inspection Points for most equipmentTightening Loose bolts, welding detachment,

loose parts, vibration or bumping noise, friction

Heat Oil tanks, motors, heaters, axles, control panels, washing/cleaning water, bearing, wiring etc.

Seiso - Cleaning

Cleaning - Inspection Points for most equipment Breakage, Breakage, cracks dent on sliding Cracks parts, handle has come off,

broken switches, wire joints come off, wires are broken orcrack dial of various pre, gauge,meters etc.

Now, Fourth ‘S’ is ...!

SEIKETSU( STANDARDISATION )

Seiketsu - Sandardisation

SEIKETSUSetting up Standards / Norms for a neat & clean workplace and details

of how to maintain the Norms(Procedure) ...


Maintain & ImproveThe Standard of :

SeiriSeitonSeiso


•Regularizing 5S activities so that abnormalities are revealed.•Make it easy for everyone to identify the state of normal or abnormal condition

•For maintaining previous 3 S, deploy visual management

Seiketsu - Sandardisation Visual Management

•It has been estimated by scientific study that 60% of all human activities starts with sight•5S is easy to do once. It is consistency that is difficult. That is why Visual Management is so important, so that evreybody will know that there is some problem.


What visual controls communicates?

It grabs one or more of our senses in order to

Alert us to an abnormalityHelp us recover quicklyPromote adherence and preventionEnable successful self management


Some method for visual communication :Colour codingUse of LabelsDanger AlertsIndication where things should be putDirectional arrows/ marksTransparent coversPerformance indicators


Some method for visual communication :

Labels:Precision management labelsInspection LabelsTemperature LabelsResponsibility labels


Points to remember in making visual control tools :

1) Make them easy to see from distance2) Put the display on the things3) Everyone can tell what is right and what is wrong4) Anybody can follow them and make necessary corrections easily5) Work place should look brighter & orderly


Some everyday visual management example :

Traffic signalZebra crossingIn car - Petrol indicator

- Speed IndicatorDirection arrowsElectric danger sign etc.


Some visual communication signs :

And, Fifth ‘S’ is ...!

SHITSUKE(TRAINING & DISCIPLINE)

Shitsuke - Training and Discipline

We need everyone to maintain 5S guidelines.

To maintain DISCIPLINE, we need to practice and repeat until it becomes a way of life.

Discipline is the Core of 5S


Discipline means making a steady habit of properly maintaining correct procedures.

Time and effort involved in establishing proper arrangement and orderliness will be in vain if we do not have discipline to maintain it.


PledgeIt shall be my constant effort to maintain my workplace in good order by

Assign a place for everything & keeping everything in its placeSorting out unwanted material periodically and discarding themKeeping my work area neat & clean everyday

Part 2

How To Implement 5S

How To Implement 5S

Step 1

Form a 5S CommitteeOR

5S Coordicator

How To Implement 5S

Step 2

Divide the Workplace

into various Zones

How To Implement 5S5S format 1 Zone at ‘work’

Group Area Type of Audit Line/ Section Zone No.

How To Implement 5S

Step 3

Allocate Zones to the relevant people

How To Implement 5S

Step 4

Start ImplementingSeiriSeitonSeiso

How To Implement 5S

Step 5

Audit the 5SImplementation Process

How To Implement 5S5S format 25S Audit Calendar For the month of :

S. No. Name Area of Audit Type of Audit Zone Dates

How To Implement 5S5S format 3 5S AUDIT CHECKLIST – SUPPORT GROUP

5S Points Mark Range Marks1. SEIRI (SORTING)a) ITEMS/PROCESS MATL/INSTRUMENTS SORTED & IDENTIFIED AS 1-10 OK, Usable immediately Usable (Spares) Good, Not Required Rework Scrapb) FILES AND RECORDS SORTED AND IDENTIFIED AS 1-5 Current/Follow up Not Required (to be sent to Record Room)c) ANY ITEM /FILES/RECORDS LYING UNSORTED 1-5

SUB-TOTAL2. SEITON (SYSTEMATIC ARRANGEMENT)a) Table, Chairs, Cupboards, Racks & Bins Neatly Arranged 1-5b) Items neatly arranged and identified as Under process/Spares/Scrap 1-5c) Arrangement of files in Filing Rack 1-5d) Any items /files lying haphazard 0 or 5

SUB-TOTAL3. SEISO (Cleanliness)a) Tables, Chairs, Machines 1-5b) Surroundings Area free of oil, chips, cotton waste etc. 1-5c) Floor, wall, (Including Glass of Windows & Ventilation) Ceiling (Tube Light, Fans & Roof) 1-5d) Measures taken to consume electricity 1-5

SUB TOTAL TOTAL

Signature of Zone Member Sign of Auditor Date Name Dept

How To Implement 5S5S format 4 5S AUDIT CHECKLIST – PRODUCTION GROUP

5S Points Mark Range Marks1. SEIRI (SORTING)a) ITEMS/PROCESS MATL/INSTRUMENTS SORTED & IDENTIFIED AS 1-10 OK, Usable immediately Usable (Spares) Good, Not Required Rework Scrapb) FILES AND RECORDS SORTED AND IDENTIFIED AS 1-5 Current/Follow up Not Required (to be sent to Record Room)c) ANY ITEM /FILES/RECORDS LYING UNSORTED 1-5

SUB-TOTAL2. SEITON (SYSTEMATIC ARRANGEMENT)a) Table, Chairs, Cupboards, Racks & Bins Neatly Arranged 1-5b) Items neatly arranged and identified as Under process/Spares/Scrap 1-5c) Arrangement of files in Filing Rack 1-5d) Any items /files lying haphazard 0 or 5

SUB-TOTAL3. SEISO (Cleanliness)a) Tables, Chairs, Machines 1-5b) Surroundings Area free of oil, chips, cotton waste etc. 1-5c) Floor, wall, (Including Glass of Windows & Ventilation) Ceiling (Tube Light, Fans & Roof) 1-5d) Measures taken to consume electricity 1-5

SUB TOTAL TOTAL


How To Implement 5S5S format 5 5S AUDIT CHECKLIST – ADMINISTRATIVE GROUP

5S Points Mark Range Marks1. SEIRI (SORTING)a) Records, files with clear Labeling 1-10b) Memos / Letters Sorted out for Filling/ Action/ Follow-up 1-5c) Any Items/Files/Records lying unsorted 0 or 5

SUB-TOTAL

2. SEITON (Systematic Arrangement)a) Work Table, Chairs and Personal Belongings 1-5b) Layout of office & office equipment (filling cabinet, Waste Paper Bins, Computers & Stationary 1-10c) Any items/ Files Lying Haphazard 0 or 5

SUB TOTAL

3. SEISO (Cleanliness)a) Tables, Chairs, Computers 1-5b) Cupboard, Filing Cabinet 1-5c) Floor, wall, (Including Glass panes of Windows & Ventilators) Ceiling (Tube Light, Fans & Roof) 1-5d) Measures taken to consume electricity 1-5

SUB TOTAL TOTAL


How To Implement 5S

5 S NOTICE BOARD 1 AREA PROBLEMS FOR GROUP 5S ASSESMENT CHART

DATE

2 ZONE

3 LEADER TODAY TODAY LAST MONYH AVERAGE AVERAGE

SEIRI

4 PARTICIPANT SEITON

SEISO

TOTAL

How To Implement 5S

Step 6 Give Recognition to best 5 S Team

Thank You

5s ppt

Documents

bins neatly

usable immediately

surroundings

zone member

items neatly

required rework

achieve systematic

total total