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5S
THE SECRET TO JAPANESE SUCCESS
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WHAT PROBLEMS DO U COMMONLY ENCOUNTER AT YOUR WORKPLACE
HIGH ABSENTEEISMHIGH TURNOVERDEMOTIVATED EMPLOYEESDISORDERED/ CLUTTERED
ENVIRONMENTMISTAKES/ERRORS
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THE SOLUTION TO ALL THESE PROBLEMS IS
5S
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5S HOUSEKEEPING TECHNIQUE
PRODUCTIVITY AND SAFETY ENHANCEMENT TECHNIQUE
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IDEA BEHIND 5SIDEA BEHIND 5S
IN ORDER TO ACHIEVE HIGH LEVELS OF QUALITY, SAFETY,AND PRODUCTIVITY, WORKERS MUST HAVE A CONDUCIVE WORKING ENVIRONMENT
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WHAT IS 5S?WHAT IS 5S?
Developed by the JapaneseHousekeeping SystemHelps Create a Better Working
Environment and a Consistently High Quality Process
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THE 5S PRINCIPLESTHE 5S PRINCIPLES
SEIRI – Organisation/Sort out
SEITON – Orderliness/Systemize
SEISO – The Cleaning/Shining
SEIKETSU – STANDARDIZE
SHITSUKE - Sustain/Discipline
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DISCOVERY OF 5SDISCOVERY OF 5S
Thirty years ago researchers started studying the secret of success of Japanese manufacturing companies
5S turned out to be the most impressive "secret"
The factories were so well organized that abnormal situations were readily apparent
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DISCOVERY OF 5SDISCOVERY OF 5S
Equipments were so clean and well maintained that any problem such as a loose bolt or leaking oil could be easily seen
This passion of cleanliness and orderliness became a hallmark of Japanese organizations
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ADVANTAGES OF 5SADVANTAGES OF 5S
If tools and materials are conveniently located in uncluttered work areas
Operators spend less time looking for items
This leads to higher workstation efficiency, a fundamental goal in mass production
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ADVANTAGES OF 5SADVANTAGES OF 5S
A clean and tidy workplace leads
to greater well being and
increased motivation
Company image improves
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ADVANTAGES OF 5SADVANTAGES OF 5S
Health and Safety is ensured Machine maintenance Quality Productivity Lean Manufacturing
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ADVANTAGES OF 5SADVANTAGES OF 5S
RESULTS IN A PLACE EASIER TO MANAGE
SMOOTH WORKING NO OBSTRUCTION
NO DEVIATION, NO PROBLEMS
B/C EVERYONE KNOWS WHERE THE THINGS ARE SPPOSEDF TO BE
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ADVANTAGES OF 5SADVANTAGES OF 5S
TIME SAVING QUICK RETRIEVALACCIDENTS & MISTAKES
MINIMIZED INCREASES SPACECREATES WORKPLACE OWNERSHIP
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ADVANTAGES OF 5SADVANTAGES OF 5S
FOUNDATION OF ALL QC TOOLS
CONTINUOUS QUALITY IMPROVEMENT
LEAN MANUFACTURINGKINDERGARTEN OF QUALITY
TOOLS & TECHNIQUES
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ADVANTAGES OF 5SADVANTAGES OF 5S
VISUAL MANAGEMENT SYSTEM
VISUAL CONTROL TO SEE THE ABNORMALITIES
SIMPLE SIGNALS THAT PROVIDE AN UNDERSTANDING OF THE CONDITION( NORMAL/ ABNORMAL)
A LOOK AT THE PROCESS REVEALS ITS DIRECTION (RIGHT/WRONG)
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Lean Production
The latest incarnation of JITBased on Toyota Production System.Waste eliminationWidely used in automotive
manufacturing & other repetitive mfg.
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It’s a mindset & commitment to achieve a totally waste-free operation that’s focused on your customer’s success… achieved by simplifying and continuously improving all processes
It’s the elimination of waste Everywhere – while adding customer value…
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Lean production cuts costs & inventories rapidly to free cash, which is critical
It also supports growth by improving productivity & quality, reducing lead times, and freeing huge amounts of resources.
From the operations perspectiveFrom the operations perspectiveFrom the operations perspectiveFrom the operations perspective
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From the operations perspectiveFrom the operations perspectiveFrom the operations perspectiveFrom the operations perspective
For example, lean production frees office and plant space and increases capacity so companies can
1. Add product lines 2. In-source component production3. Increase output of existing products
without acquiring new facilities.
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KINERGARTEN OF ALL THE QC TOOLSKINERGARTEN OF ALL THE QC TOOLS
5S IS THE STARTING POINT OF ALL THE QC TOOLS
COULD BE SAID AS THE PRE- REQUISITE OF ALL QC TOOLS
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METHODOLOGY OF 5S
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1. ORGANISATION(SEIRI)1. ORGANISATION(SEIRI)
Decide what you need
Remove unnecessary clutter
All tools, gauges, materials, classified and then stored
Remove items which are broken, unusable or only occasionally used
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RED TAG TECHNIQUERED TAG TECHNIQUE
GIVE STAFF RED LABELSASK STAFF TO GO THROUGH
EVERY ITEM IN THE WORK PLACEASK IF NEEDED & THOSE THAT
ARE NEEDED,IN WHAT QUANTITYNOT NEEDED RED TAG IT STORE IN THE RED TAG AREA
RED TAG
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For wavering itemsFor wavering items
PLACE THE SUSPECTED ITEMS IN THE RED TAG AREA FOR ONE WEEK
ALLOW THE STAFF TO REEVALUATE THE NEEDED ITEMS
AT THE END OF WEEK THOSE WHO NEED ITEMS SHOULD BE RETURNED
REDTAG
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ORGANISATIONORGANISATIONPRIORITY FREQUENCY OF USE HOW TO USE
Low Less than once per year
Once per year
Throw away
Store away from the workplace
Avg. Once per month
Once per week
Store together but offline
High Once Per Day Locate at the workplace
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2. ORDERLINESS(SEITON)2. ORDERLINESS(SEITON)
ONCE YOU HAVE ELIMINATED ALL THE UNNEEDED ITEMS
NOW TURN TO THE LEFT OVER ITEMS
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ORDERLINESS(SEITON)ORDERLINESS(SEITON)
Organise layout of tools and equipment
–Designated locations–Use tapes and labels –Ensure everything is available as it is needed and at the “point of use”
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ORDERLINESS(SEITON)ORDERLINESS(SEITON)
Workplace Checkpoints:- Positions of aisles and storage places
clearly marked? Tools classified and stored by frequency
of use? Pallets stacked correctly? Safety equipment easily accessible? Floors in good condition?
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3. SEISO (CLEAN/SHINE)3. SEISO (CLEAN/SHINE)
Create a spotless workplace
Identify and eliminate causes of dirt and grime – remove the need to clean
Sweep, dust, polish and paint
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SEISO (CLEAN/SHINE)SEISO (CLEAN/SHINE)
Divide areas into zones
Define responsibilities for cleaning
Tools and equipment must be owned by an individual
Focus on removing the need to clean
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4. SEIKETSU (STANDARDISE)4. SEIKETSU (STANDARDISE)
Generate a maintenance system for the first three
Develop procedures, schedules, practices
Continue to assess the use and disposal of items
Regularly audit using checklists and measures of housekeeping
Real challenge is to keep it clean
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5. SHITSUKE (SUSTAIN / DISCIPLINE)5. SHITSUKE (SUSTAIN / DISCIPLINE)
Means inoculate courtesy & good habits Driving force behind all 5S Deming’s point number 1: Constancy of
purpose Make it a way of life Part of health and safety Involve the whole workforce* Develop and keep good habits
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LITMUS TEST FOR 5SLITMUS TEST FOR 5S
30 SECOND RULE ONE MUST LOCATE THE ITEM WITH
IN 30 SECOND IF 5S IS PROPERLY IMPLEMENTED
ALSO APPLIES TO THE ELECTRONIC RECORDS RETRIEVAL
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WHAT U HAVE COME ACROSS AT THE END OF DAY
WHAT U HAVE COME ACROSS AT THE END OF DAY
Followings can be harnessed form the 5S
1. NEAT & CLEAN WORKPLACE
2. SMOOTH WORKING
3. NO OBSTRUCTION
4. SAFETY INCREASES
5. PRODUCTIVITY IMPROVES
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Cont.Cont.
6. QUALITY IMPROVES
7. WASTAGE DECREASE
8. MACHINE MAINTENANCE
9. VISUAL CONTROL SYSTEM
10. EMPLOYEES MOTIVATED
11. WORKSTATIONS BECOME SPACIOUS