5 S PRESENTATION

5 S (Pillars of theVisual factory)

Why the five Pillars are the foundation of 5S improvement Activities

When people first learn about the five pillars it may be hard for them to understand why.Here is an everyday explanationExample : People practice the five pillars in their personal lives without even noticing it. We practice Sort & Set in Order when we keep things like wastebaskets , towels & tissues in convenient & familiar places. When our home environment becomes crowded & disorganized, we tend to function less efficiently

Sort & Set in Order are in fact the foundation for achieving Zero Defects, Cost Reductions, Safety Improvements & Zero Accidents

Common types of Resistance to 5S Implementation

What’s so great about Sort & Set in Order

Why clean when it just gets dirty again Implementing Sorting & Setting in Order We already implemented Sort & Set in Order We did 5S years agoWe are too busy for 5S activitiesWhy do we need to implement the five

pillars

Introduction to the Five Pillars of 5SSEIRI (Sort) Organization :Means clearly distinguish needed items from unneeded items & eliminate the latter.Sort, The first pillar of visual workplace , corresponds to the Just in Time ( JIT) principle of

* Not needed at all at Gemba * Not needed here * Needed but not now* Needed but not so much

In other words , Sort means that you remove all items from the workplace that are not needed for current production(or clerical ) operations.

Sort does not mean that you throw out the only items that you are sure you will never need. Nor does it mean that you simply arrange things into neat , straight patterns . If you sort , you leave only the bare essentials : When in doubt , throw it out. This principles is a key part of Sort in the context of the five pillars.

KEEP IN MIND…….!!!!

“ THE RED TAG SYSTEM IS FOR ONE TIME USE ONLY, IT IS NOT AN ON GOING ACTIVITY FOR FUTURE CLEAN UPS ”

“ THE DISPOSAL OF RED TAGGED ITEMS SHOULD BE DONE IN MAX 30 DAYS , IT IS NOT A EXTENTION OF STORE ”

“DEVELOP VISUAL ARRANGEMENT STORAGE AREAS WHICH CLEARLY INDICATE WHERE ITEMS ARE STORED & HOW MANY ARE STORED THERE”

“NUNECESSORY ITEMS OFTEN BECOME INVISIBLE TO THE PEOPLE WHO ARE AROUND THEM ”

PRESENT PRACTICES ARE BEST POSSIBLE

PRESENT PRACTICES ARE BEST POSSIBLE

Seiton (set in order) Orderliness

Means keep needed items in the correct place to allow for easy & immediate retrieval.

Or Set in order that you arrange needed items so that they are easy to use & label them so that anyone can find them and put them away. The key word in this definition is “ANYONE.”

The set in order pillar is the core of standardization. This is because the workplace must be orderly before any type of standardization can be implemented effectively.

Seiso (Scrub) (Shine) (Cleanliness)

Keep the workshop swept & clean

Another key purpose is to keep everything in top condition so that when someone needs to use something , it is

ready to be used .

Seiketsu (Standardize) Standardized Cleanup

Standardize differs from Sort, Set in Order & Shine . These First three pillars can be thought of as activities, as something we do.

Standardize is the method you use to maintain the first three pillars - Sort, Set in Order& Shine

Standardize, the fourth pillar of our VISUAL WORKPLACE.

Shitsuke (Sustain) Discipline

Sustain means to make a habbit of properly maintaining correct procedures.

FIVE SFIVE TERMS BEGINNING WITH S UTILIZED TO CREATE A WORKPLACE SUITED FOR VISUAL CONTROL & LEAN PRODUCTION.

SEIRI - MEANS TO SEPARATE NEEDED TOOLS,PARTS, & INSTRUCTIONS FROM UNNEEDED MATERIALS & TO REMOVE THE LATTER .SEITON -MEANS TO NEARLY ARRANGE & IDENTIFY PARTS & TOOLS FOR EASE OF USE.SEISO - MEANS TO CONDUCT A CLEANUP CAMPAIGN .SEIKETSU - MEANS TO CONDUCT SEIRI, SEITON & SEISO AT FREQUENT, INDEED DAILY, INTERVALS TO

MAINTAIN A WORKPLACE IN PERFECT CONDITION.SHITSUKE- MEANS TO FORM THE HABBIT OF ALWAYS FOLLOWING THE FIRST FOUR Ss .

ACTIVITIES : Seiri : Not needed at all at GembaNot needed hereNeeded but not nowNeeded but not so much

DICISION OF NEEDED BUT HOW MUCH SHOULD BE AT GEMBA

UNNEEDED MATERIAL TO BE MOVED TO RED TAG AREA Attack in this sequence

C – CleaningO – OilingT – Tightening

Jishu Hozen : Restoration of Basic Condition & kill the Accelerated distortion.

1. Initial Clean up2. Countermeasures against outbreaks3. Tentative standards

1. Initial Cleaning : *Observe abnormality ( Fugai ), should be done in inspection. *Attach a tag on abnormality *Cleaning with Meaning

: Identify Dirty/Loose/Unoiled : Identify Difficult to Access. : Identify NonStandard ways

a) Cleaning with Meaning

Clean from top to bottom. Find abnormalities while cleaning & put red tag

b) Oiling :To make sure that lubrication is reaching where required in right quantity

c) Tightening:Tighten all loose nuts and bolts or anything loose (remove red tag)

2. Make a list of necessary material required on machine and the quantity required

1. For Storing any items, following seven points should be considered :

1. Search Free2. Count Free3. Air Free4. Climb Free5. Bend Free6. First in First Out

7. Heavy things on Lower Shelves

8. Store should be lighted & ventilated properly.

FEW EXAMPLES

Maintenance Room

( Before )

Maintenance Room

( After )

Maintenance Room

( Before )

Maintenance Room

( After )

Before

After Right material at Right Place

Incoming Store

Before

After

Indexing & Differential Gears (Timing Gears)

Search Free

Before

After

Hobbing Fixtures (Timing Gears)

Search Free

Before

After

Hobbing Machine (Timing Gears)

Search Free

Before

After Visualization

Model Machine (HB-02)

Before

After

Lister Petter Cell (CN-06)

Search Free

Before

After

Search Time reduced from 5 min. to 10 sec for checking Lead Profile & PCD R/o.

Standard Room

Before

After Visualization

Maintenance Room

2 S Seiton• SELECTED PROPER PLACE FOR LISTED ITEMS.

•VISUALISATION

Search Free

Maintenance Room

After Search Free

Final Inspection ( Timing Gear)

Before

Before

After Search Free

CNC Drilling Machine

Before

After

Visualization

M-2 Cell (Two Wheeler )

WHY TO DO 5S ?

ORGANIZED WORK PLACE RESULTS IN:

1. An increase in Quality2. An increase in productivity3. A clean work place4. A clean work place which creates safe workplace5. Reduction I required floor space6. Gives quantifiable results like reduction in set up time

Thanks…..!!!