5’s’-program-on-zero-defects ppt
TRANSCRIPT
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SEMINAR ON5’S’ Program on Work place Organization
&Standardization
PRESENTED BY-AMIT SHUKLAUSN- 1DS04ME009DEPARTMENT OF MECHANICAL ENGG.DAYANADA SAGAR COLLEGE OF ENGG.BANGALORE-78.
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An Ancient Prayer
From the cowardice,
That Makes us,
Shrink from the Truth ;
From the laxness,
That Keeps us ,
Content with Half Truth ;
From the Arrogance,
That Makes us Believe,
That We know All truth ;
O’ My Lord,
Deliver Us.
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How Adults Learn & Retain…
• 20% of what they hear
• 30% of what they see
• 50% of what they hear and see +
• 70% of what they hear, see and say
+ +
• 90% of what they hear, see, say and do
+ + +
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But First...Death by Initiative
This is NOT a new initiative!
A NewWay ofDoing
Business!
It is NOT a new way of doing business!
It is merely doing what we alreadydo, but doing it BETTER!
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Characteristics of PokaYoke Devices
Simple and cheap
Part of the process, permitting 100% inspection
Placed close to where the mistakes occur,providing quick feedback.
Designed to stop a particular mistake
A detection device cannot provide a completeerror proof solution
Necessary and not a sufficient solution.
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Join the Run
5 ‘S’ is ComingJoin The Run
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What is 5’S’ ? A basic, fundamental, systematic approach for productivity, quality and safety improvement in all types of businesses.
The Five S program focuses on having visual order, organization, cleanliness and standardization. The results you can expect from a Five S program are: improved profitability, efficiency, service and safety.
The precipices underlying a Five S program at first appear to be simple, obvious common sense. And they are. But until the advent of Five S programs many businesses ignored these basic principles.
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What is 1’S’ ? This is step 1 in a Five S program:
"Sorting" means to sort through everything in each work area. Keep only what is necessary. Materials, tools, equipment and supplies that are not frequently used should be moved to a separate, common storage area. Items that are not used should be discarded. Avoid keeping things around just because they might be used, someday.
Sorting is the first step in making a work area tidy. It makes it easier to find the things you need and frees up additional space. The Principle involved is Sort In – Sort Out .
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Mixed items - Before Sorting Items arranged - After Sorting
Tools placed - After Sorting
Plug pins placed - After Sorting
Pins & screws placed - After Sorting
All Tools,pins,screws, are lying – before Sorting
Sorting : Remove the Unneeded items, Rearrange /Regroup the Needed Items as per Predefined Categories
Sort In - Sort Out
1 ‘S’ – Sort
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How is 1’S’ carried
out ?
Keep the wanted things & remove the unwanted things using Red Tag Procedure .
Red Tags Procedure : Red Tags Procedure :
Red Tag Procedure is first step of sort activity. All items at the work place are critically analysed for their use & availability at work place. All unneeded items & those in excess of their normal use are removed to a remote area marked as Red Tag Holding Area. The idea of this activity is to keep only those items in that area which are relevant & required in relevant quantities. All items shifted to red tag area carry a red tag which is filled with, quantity, reason for red tag, tagged by, date of tagging, reason for tagging disposal proposal & action by, review date & status of disposal. Each tag is allotted a unique S. No. Also there is an action plan updated with every addition to red tag area to ensure that items don’t lie there indefinitely, but are disposed at appropriate times.
Item Name:
Quantity:
Reason for red tag
Identified by:
Date:
Reason1.Obsolete2.Not needed now (once/year)3. Not reqd in the qty stored4.Not reqd in that area5.Defective/ scrap6.Use not knownDisposal1.Discard2.Return3.Sell4.Move to separate storage area5.ReworkDisposalActionBy:DateReview/ DisposedRed-tag file no.
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What are benefits of 1’S’ ?
When should be 1’S’ activity started ?
Creation of space is single biggest advantage of 1’S’
Generally if you are facing problem of lack of space, go for 1’S’ & space problem is eliminated.
Sometimes one gets surprised with the amount of space released as a result of 1’S’ activity.
The other advantage is money released due to sale of unwanted items lying unattended for long times.
1’S’ Being the first the step of 5’S’ program should be starting point.
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Where is 1’S’ useful ?
What are the success indicators of 1’S’?
1’S’ is useful in factories work areas , offices & homes alike.
Housewives find it maximum useful. Even Municipal corporations are getting their staff trained in steps of 5’S’ as they realize immense benefits of it.
The space generated & money released are the success
indicators.
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Seiri – Sorting Out
SEIRI
Unnecessaryitems
Necessary items
How often do youneed them?
Is disposalexpensive?
Resale value?
Immediatethrow-away
Seldom but can'tthrow away
Sometimes
Always
Storage location
Action
Minimize cost ofdisposal
Try to sell
Throw awayquickly
Separate
A little far away
Close
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What is 2’S’ ? 2s stands for Set in order
The Principle involved is ’Place for everything & Everything in place’
When is 2’S’ Activity started?
2’S’ Activity is started immediately after 1’S’. This sequence has to be followed strictly.
How is 2’S’ activity carried
out ?
2’S’ activity is carried out making use of lines , labels & signage.
Lines Standard colour & widths are used for marking locations
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Seiton – Set In Order
SET IN ORDER
TOOLS/GUAGES
items
INPUT/OUTPUT MTLSM
Is it close at hand?
Is the area marked ?
Is the items labeled? labeled
Does it follow storage freedom ?
Is the area marked?
Storage location
Storage location
On a template
As per operation requirement
Six freedom rules
Defect fact cards 3W1E cards
On floor or stand
Is the rejects area marked separately?
Is the matl Identified?
On floor or stand
Is the limits set? Is the limits set? As per prodn req
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Labels
Signage
Labels of standard fonts & sizes are used to mark locations, equipments,bins & containers.
Fire extinguishers, exit ways are marked using standard symbols.
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What is benefit of 2’S’ ?
Time for searching tools , items files etc is eliminated to zero.
Before After
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What is 3’S’?
3’S’ Stands for shine.
The principle involved is ‘cleaning with meaning’
Cleaning methods should address questions like what is being cleaned, where is it being cleaned, how is it being cleaned, who will clean & when will it be done.
The cleaning schedule should include walls, floor, roof etc.
Locations for cleaning material must be marked & 2s for cleaning material should not be ignored.
Abnormalities like loose wires, leakages must be tagged promptly.
Cleanliness is also helpful to notice damages on equipment such as leaks, breakage and misalignment.
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Seiso- Shine
SHINE
MATERIALS
items
CALENDAR
Is it close at hand?
Is the area marked ?
Is the items labeled? labeled
Recording with meaning ?
Is the method clear
Cleaning Check list
Storage location
In a stand
As per operation req
Tags/Register
Daily/weekly
As per the area
Who is to clean?
Is what to clean identified?
On floor or wall
Is the limits set? Is the frequency set As per process req
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What are the benefits of 3’S’ activity?
How is 3’S’
activity done?
3’S provides safe, immaculate & pleasant surroundings.
It is very important to boost the morale of working people
Clean thoroughly the workplace inside out. Roofs, Equipments , floor.
Start from the top & come down
gradually.
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3’S’ Prepare the cleaning check-lists & follow them.
S.No
What When How Who
1 Floor Cleaning
Shift Start & EndWhenever there is spillage.
Floor Mops Brooms
Sweeper & certified by SIC
2 Machine cleaning
Shift Start & EndWhenever there is spillage.
Waste Cloth & Solvent
MC Operator
3 Wall Cleaning from Dust & Cobwebs
1st Day of Month
Brooms with extended handles
Sweeper & certified by SIC
4 Work Tables
Shift Start & EndWhenever there is spillage.
Waste Cloth & Solvent
M/C Operator
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What is 4’S’? 4’S’ stands for standardization of 1’S’, 2’S’ & 3’S’.
The Principle involved is standardisation of above 3s i.e. defining clearly what is required level to be achieved.
The workplace must have display of required standards. Area map. Audit sheets, work instructions,Do’s & Don’ts in that workplace.history cards for equipments, COT checklists, Safety check lists, production performance graphs, Quality performance graphs, planned maintenance records, OEE graphs, improvement tracking graphs.
When is 4’S’ carried out?
4’S’ is carried out after completing 3’S’ activity.
It is important to follow the sequence as bypassing the steps can lead to no benefit of any step.
The idea is workplace should speak itself giving an idea about state of affairs in the
shop.
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Seiketsu - Standardise
Prepare a list of all standards that needs to be located in the work area
this will include, area map, 5 S audit sheet
PICTORIAL WORK INSTRUCTIONS FOR-OPERATION & DO'S and DONT'SSMED, AM-COT, SAFETY POINTS
HISTORY CARDPLANNED MAINTENANCE-RECORD AND PLANSCURRENT PERFORMANCE GRAPHS/TRENDS-
PRODUCTION INFORMATION AS OF CURRENTOUTPUT PERFORMANCEQUALITY PERFORMANCE
OEEIMPROVEMENT'S TRACKING GRAPHS/CHARTS
SKILL LEVELANY OTHER INFO THAT MAY BE REQUIRED FROM TIME TO TIME
Audit both the area and equipment for all the above work instructions and usage- no ncr's
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What is 5’S’ activity ?
5’S’ stab\nds for sustain.
Sustain activity is carried out using following steps :
Train all operators in observing SOPs & Red Tag Procedures.
Place of neat storage of personal items.
Process owners carry out Daily Audit & 5’S’
Teams meet once a week.
Recognition for Best Area as a rolling trophy.
How is 5’S’ activity done ?
Sustaining is done through Audits & Training
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5 ‘S’ Sustain
S.No. Action Who Target Date
Action Plan
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Conclusions:
Think simple
Think specific
Think attributes
Think early
Think responsive
Think reuse
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REFERENCES
1. Besterfield, D.H., 2001. Quality Control, 7th edition, New Jersey: PrenticeHall International.
2. Straker, D., 1995. A Toolbook for Quality Improvement and problem Solving,New York: Prentice Hall.
3. Turner, W.C., Mize, J.H., Case, K.E. and Nazametz, J.W., 1993. Introductionto Industrial and Systems Engineering, New Jersey: Prentice HallInternational.
4. Shigeo, S., 1986. Zero Quality Control: Source Inspection and the Poka YokeSystem, Massachusetts and Norwalk: Productivity Press Cambridge.
5. Shigeo, S., 1988. Poka Yoke: Improving Product Quality by PreventingDefects, Massachusetts and Norwalk: Productivity Press Cambridge.
6. Woo, C.C., 2007. Microcontroller Based Motorized Cleaner, Faculty ofElectrical Engineering, Universiti Teknologi Malaysia, UnpublishedUndergraduate Project.
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Thank you