intimate fashion 5s
TRANSCRIPT
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To Have the Right Things In the Right PlaceMaking the Workplace Bright and Productive
Intimate’s 5S Vision
From Basics to Benchmarks
Intimate’s 5S Journey
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5S @ Intimate
Our 5S journey started during mid 2000 after seeing our Srilanka factory “BODYLINE Pvt. Ltd “
Training program was conducted for all employees about 5S
Posters were put up at all strategic locations in the factory about 5S
A contest was launched to all the employees for designing a suitable logo for the 5S movement at Intimate Fashions
Seiri day was celebrated to launch the first step of 5S on 10th October , 2000
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SEITON @ Intimate
SEISO @ Intimate
SEIKETSU @ Intimate
SHITSUKE @ Intimate
SEIRI @ Intimate
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5S is a simple but highly effective set of techniques
5S methodology was developed in Japan
5S is the foundation for any continuous improvement
5S removes waste from work environment through
better workplace organization, standardization, visual
communication and general cleanliness
5S factories are so well organized that abnormal situations
will be readily apparent
What is 5S ?
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What are the 5Ss ?
5Ss5Ss Japanese English Meaning
1 S SEIRI SORT Remove unwanted items
2 S SEITON SYSTEMATIC
ARRANGEMENT
A place for everything and everything in its place
3 S SEISO SPIC&SPAN Cleaning with inspection
4 S SEIKETSU STANDARDISE Establish Standards for first 3Ss
5 S SHITSUKE SELF DISCIPLINE
Sustain & improve the first 4Ss
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SEIRI- SORT
Remove waste, scrap, unused, sub-standard, excess items from
the workplace
Change the mental model of “Do not throw it away-it might
come in useful some day”
An effective visual method to identify & remove these
unwanted items is called Red Tagging
Seiri is eliminating unnecessary items from the workplace.
Space is freed for better utilization. Ensures Safety
Remove unwanted items
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All unwanted items to be removed and placed in a
specially demarcated area called red tag area.
Unwanted items to be tagged with a red tag slip
Red tag slip will describe the item, quantity and date of
tagging
This process is for evaluation of the red tagged items
Occasionally used items are moved to a more organized storage
location outside of the work area from where unwanted items are
discarded
Guidelines to be framed for red tagging to prevent loss of
useful items
Red Tagging
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SEITON-SYSTEMATIC ARRANGEMENT
Keep the right things in the right place and replace them in their respective place after usage
Use proper visual identification indicators Make sure storage is safe, to protect the item being
stored and also to prevent people from harming themselves when storing and retrieving
Do not store heavy items at the top making storage cupboards unstable
Seiton is keeping the needed items (those remaining after Sort) in the correct place to allow for easy and quick retrieval.
A place for everything and everything in its place
Better Inventory management.
Reduces Search time.Easy and Quick retrieval.
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SEISO-SPIC&SPAN
Spend at least 5 Minutes daily for cleaning
Use appropriate tools for cleaning
While Cleaning also inspect for damage,defects and potential problems
Clean the Hidden areas also
Cleaning without care can cause more damage
Inculcate the mindset “It is My Duty to Clean My Place”
Seiso is Keeping the work place clean and also inspecting while cleaning
Cleaning with meaning
Equipment life is improved.Future problems are proactively identified and corrected
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SEIKETSU- STANDARDISE
Establish uniform standards and procedures for labeling,
colour codes, indicators and safety norms
Display visual signage and control wherever possible
Establish proper Checklists, Responsibility Lists and
Schedules
Seiketsu is developing standards & responsibilities for the first 3Ss
Increases Quality & Productivity. Mistakes are eliminated
Establish Standards for first 3Ss
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SHITSUKE-SELF-DISCIPLINE
Provide continuous guidance and training
Conduct regular 5S audits , display the result
Analyze audit findings & act
Create Interest & Involvement thro’ publicity & competitions
Ensure everyone is committed to “5S is my Responsibility”
SHITSUKE is perhaps the toughest of the 5S’s
Shitsuke is to implement mechanisms that are required to ensure the first 4Ss
5S becomes a Habit
Sustain & improve the first 4Ss
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Seiri day was inaugurated by H.E. Mr. Tetsuya Unno the Vice Consul at the Consulate General of Japan for South India
The Chief guest unveiled the 5S logo
Prizes were distributed to the winners of the logo contest. (4 prizes out of 65 entries)
Red tag areas demarcated in every department
Red tags printed and issued to every department
Seiri was done throughout the factory on that day and all the red tagged items were moved to a common red tag area for the factory
SEIRI Day @ Intimate
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SEIRI Day @ Intimate
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Red Tag
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SEIRI on Notice Board
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Locker area
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Main Entrance
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Pathway to Reception
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Main Entrance
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Pathway to Reception
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Front Portico
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Entrance to Office
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Reception
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Office Corridor
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Way to Production Floor
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Sewing Floor
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Material Testing Lab
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Facility Block
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Facility Block
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Canteen Service Counter
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Landscaping
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Landscaping
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Toilet
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Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Road to Loading Deck
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Stationery Template
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Visual Identification
Wrong placement
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Key Listing
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Staff Tracer Board
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Labels for Switch & Lights
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Medical Center
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Finished Goods Packing Area
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
WIP (1,50,000 components/line)
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
5S TEAM FORMATION
5S REVIEW BOARD
CEO & HOD’s
5S CHAMPION
STANDARDIZATION
TEAM
TRAINING
TEAM
AUDIT
TEAM
PUBLICITY
TEAM
Team Leader Team Leader Team Leader Team Leader
Members Members Members Members
Review once in 2 mths
New team every year
Chosen from volunteers
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
5S Team’s Responsibilities
• Standardization TeamStandardization Team
– To introduce standards for the first 3SsTo introduce standards for the first 3Ss
• Training TeamTraining Team
– To provide continuous education to all employees on 5STo provide continuous education to all employees on 5S
• Audit TeamAudit Team
– To schedule and conduct 5S auditsTo schedule and conduct 5S audits
• Publicity TeamPublicity Team
– To innovatively find ways of creating interest & To innovatively find ways of creating interest &
involvement on 5S with our employeesinvolvement on 5S with our employees
– To spread the awareness on 5S in our societyTo spread the awareness on 5S in our society
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Training for Bus,Van & Car Drivers
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
5S Audits in Floor
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Audit Results - Department
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Audit Results - Intimate
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
5S Corner
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
5S @ Home - Home Kit
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Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202.
5S @ HOME – One of Our Employee’s Home
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
INTEROFFICE COMMUNICATION
PURCHASE DEPARTMENT
TO : DATE : FROM : REF NO : SUBJECT : Best regards,
Interoffice Memo – Approved Format
Other Documents standardized are • Business Correspondence Letter• Minutes of Meeting• Fax Communication
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Meeting Room – Status Indicator
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Tiger Lines
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Electrical Switch panel
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Air Conditioner Chiller Plant
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Less Frequent
File Colour Codification
Department colour
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Head Supervisor Production Mechanic
FINISHED GOODS Sewing Machine Operator
Colour Coding for Uniforms Pregnant
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
INTEROFFICE COMMUNICATION
PURCHASE DEPARTMENT
TO : DATE : FROM : REF NO : SUBJECT : Best regards,
Interoffice Memo – Approved Format
Other Documents standardized are • Business Correspondence Letter• Minutes of Meeting• Fax Communication
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Meeting Room – Status Indicator
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Tiger Lines
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Electrical Switch panel
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Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Air Conditioner Chiller Plant