QIMPRO CHALLENGE – 1

POOR 5S

SUBMITTED BY:(B.TECH (CS) 2ND YEAR)

TWINKLE SINGHAL (RASHI B.TECH (2ND YEAR) CS)

5S

THE SECRET BEHIND JAPANESE

SUCCESS

The 5S process is one of the most fundamental and widely applied components of lean manufacturing

Developed by the Japanese Housekeeping System Helps create a “Better Working Environment” ,

a “Consistently High Environment” and a “Consistently High Quality Process”.

SEIRI -Organization/Sort outSEITON -Orderliness/SystemizeSEISO -The Cleaning/ShiningSEIKETSU -StandardizeSHITSUKE -Sustain/Discipline

Decide what you need.Remove unnecessary clutter and dispose it.All tools, gauges, materials, classified and then

stored.Remove items which are broken, unusable or

only occasionally used.

Organize layout of tools and Designated locationsUse tapes and labels. Ensure everything is available as it is needed and at the “point of use”.Prevent waste and loss of time.Ensure first-come-first-served basis.Make workflow smooth and easy.

Create a spotless workplace. Identify and eliminate causes of dirt and grime .Sweep, dust, polish and paint.Divide areas into zones.Define responsibilities for cleaning.Tools and equipment must be owned by an

individual.Focus on removing the need to clean.

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

Means inoculate courtesy & good habitsDriving force behind all 5SMake it a way of life Part of health and safety Involve the whole workforceDevelop and keep good habits

POOR 5SAs we know that, there are lot of benefits to be gained by putting a 5s process in place but if it fails to implement 5s then that place is said to be have poor 5s. Thus, a poor 5s means lack of sortation, cleanliness, conformity, arrangement, ordination, discipline, neatness.It means that there is not a complete and perfect implementation of 5s i.e. ‘seiri’, ‘seiton’, ‘seiso’, ‘seiketsu’, ‘shitsuke’.Here are some pictures which shows poor 5s:-

Recommendation and their implementation :

Form the small groups of people that will perform the following job:Creating awareness among the people about 5S.Motivate them to clean their workplace thrice or more a day.The things which are not in use, it must be thrown away or store it in a separate area.Tell them to arrange the things in such a manner that they should get it in less than 30 seconds.

Also for the proper 5S , a proper discipline must be followed.Regular cleaning decreases the accumulation of cuttings, shavings ,dirt and other substances that can contaminate production process and result in defects.Painting the machines and the equipment light colors and cleaning the windows decreases energy needs associated with lightning.Painting and cleaning makes it easier for workers to notice spills , leaks and defaults.

Organizing equipment , parts and materials so they are easy to find can significantly reduce unneeded consumption.

5s visual cues(e.g. signs , placards , scoreboards , laminated procedures in workstations) can be used to raise employ understanding of proper waste handling and management.

Lesson learned during project :

Benefits of 5S:Workplace will become cleaner and better organized.Lead-time reduced Defects reduced.Clear methods and standards are established.Space usage is improved.

Benefits by implementing “SEIRI” :Necessary items are identified and positioned at right location.Unwanted items and searching time is reduced.Working environment is improved.

Benefits by implementing “SEITON”:Items easily located, stored and retrieved.Right item, right place , right quantity and right method (4R) are in place.

Benefits by implementing “SEISO” :Higher quality work and projectsMore comfortable and safer work environment.Lower maintenance cost.Creates positive impression on others.

Benefits by implementing “SEIKETSU”:Better work place standards.Improvement in operation and workflow.

Benefits by implementing “SHITSUKE” :Compliance to work place rules.Adoption of best practices.Enhance operation effectiveness in a better working environment.

THANK YOU!