Necessity of 5SSEIRISEITONSEIKETSUSEISOSHITSUKEWorkplace improvementMGM*

THE 5 WORDSMGM*5S is a method that uses five Japanese words which start with the letter S

5 S5 STEPS TO A BETTER WORKPLACEMGM*

WHY 5 S?The Purpose of 5S is to promote a safe and efficient work environmentNot just a cleaning campaign, 5S is a way to set a new standard that we all agree on and help us get the discipline we need to maintain it.By Implementing the 5SOpportunity to improve the own workplaceTeam involvement & Problem solving opportunities appears.5S gives visible and Motivating ResultsFirst step in the implementation of Lean Manufacturing, TPM an Kaizen.

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REASONS TO IMPLEMENT 5SImproved SafetyNo items on the floorTherefore fewer slips or fallsSafety device in their right placesLess dustMGM*

REASONS TO IMPLEMENT 5SImproved SafetyFewer break downsFewer strange errors from electronic systemsLess wear from dust or grit in moving partsMGM*

REASONS TO IMPLEMENT 5SImproved SafetyFewer break downsBetter work EnvironmentA clean & well functioning workplaceFix the unsafe & cluttered work stationsMGM*

REASONS TO IMPLEMENT 5SImproved SafetyFewer break downsBetter work EnvironmentLess Environmental ImpactLeakages such as oil will easily be spottedUsing less floor space may reduce energy consumptionMGM*

REASONS TO IMPLEMENT 5SImproved SafetyFewer break downsBetter work EnvironmentLess Environmental ImpactFew human errorsEasy to do it right than wrongSafety guards placed properlyLess clutter, fewer visual distractions& easy access to tools and materialsMGM*

REASONS TO IMPLEMENT 5SImproved SafetyFewer break downsBetter work EnvironmentLess Environmental ImpactFew human errorsMay find problems earlierWhen you do 5S , you inspect the sameMGM*

REASONS TO IMPLEMENT 5SImproved SafetyFewer break downsBetter work EnvironmentLess Environmental ImpactFew human errorsMay find problems earlierNo searchingEffective tools at the right placeMGM*

REASONS TO IMPLEMENT 5SImproved SafetyFewer break downsBetter work EnvironmentLess Environmental ImpactFew human errorsMay find problems earlierNo searchingHigher moraleThrough teamwork and visible resultsMGM*

REASONS TO IMPLEMENT 5SImproved SafetyFewer break downsBetter work EnvironmentLess Environmental ImpactFew human errorsMay find problems earlierNo searchingHigher moraleGoodwillHelpfulness to create an impression.MGM*

THE 5 PHASES IN 5SMGM*

STEP 1 - SORTINGMGM*Sorting is a team activity that will be carried out by the production an d maintenance personnel togetherSorting has two purposesRemove unnecessary objectsReduce waste

REMOVE UNNECESSARY OBJECTSMGM*Go through the whole plantLook forMaterialsBehind or under machinesRejectsForgotten materials

REMOVE UNNECESSARY OBJECTSMGM*Go through the whole plantLook forMaterialsToolsNot in useWorn out or brokenCustom-made tools (made of steel wire/tape/etc-Replace by real tools

REMOVE UNNECESSARY OBJECTSMGM*Go through the whole plantLook forMaterialsToolsSpare partsBrokenSurplus InventorySpare parts for machines no longer in use

REMOVE UNNECESSARY OBJECTSMGM*Go through the whole plantLook forMaterialsToolsSpare partsOut-of-date DocumentationInstructionsBindersManuals

REMOVE UNNECESSARY OBJECTSMGM*Go through the whole plantLook forMaterialsToolsSpare partsOut-of-date DocumentationBulletin boardOutdated noticesIrrelevant information

REMOVE UNNECESSARY OBJECTSMGM*Go through the whole plantLook forMaterialsToolsSpare partsOut-of-date DocumentationBulletin boardOther stuffOutdated computer hardwarePacking MaterialOutdated protective equipment

REMOVE UNNECESSARY OBJECTS ?MGM*Look at each objectAsk yourself, Do we need it at all?If not Discard it or sell itAsk yourself, Will we need it soon?If not Put it in proper storage eg:- spare parts, etc.Is it working , but..Too difficult to useIn correct designToo time consuming to useHas a high risk for injury/quality?Not easy to accessible

REMOVE UNNECESSARY OBJECTS ?MGM*Each item to be discarded or corrected is marked with a red tag

WASTE ELIMINATIONMGM*The second purpose of sorting is to reduce waste and generate ideas for improvementsWe will try to identify every thing that is hindering us from working safely and efficiently

WASTE ELIMINATIONMGM*Try to identify every thing that is hindering us from working safely and efficientlyWork instrutionsDo we have them?Are they up-to-date?Are they in use? If not why not?

WASTE ELIMINATIONMGM*Try to identify every thing that is hindering us from working safely and efficientlyWork instructionsSafetyWhat measures should we take to eliminate the risk of fire and accidents?Remove clutterImprove unsafe electrical installationsReplace broken safety devicesRepair broken components

WASTE ELIMINATIONMGM*Try to identify every thing that is hindering us from working safely and efficientlyWork instructionsSafetyEnvironmentWhat measures do we need to minimize or prevent damage to the environment?

WASTE ELIMINATIONMGM*Try to identify every thing that is hindering us from working safely and efficientlyWork instructionsSafetyEnvironmentTools and equipmentAnything missing ?Anything not working properly ?Anything in need of improvement?

WASTE ELIMINATIONMGM*Try to identify every thing that is hindering us from working safely and efficientlyWork instructionsSafetyEnvironmentTools and equipmentInconvenient work positionsSeat & work s/fs at the right heightAwkward angles for moving materials

WASTE ELIMINATIONMGM*Try to identify every thing that is hindering us from working safely and efficientlyWork instructionsSafetyEnvironmentTools and equipmentInconvenient work positionsDeferred maintenanceTemporary repairs/not properly securedOld equipments/technical errors

WASTE ELIMINATIONMGM*Try to identify every thing that is hindering us from working safely and efficientlyWork instructionsSafetyEnvironmentTools and equipmentInconvenient work positionsDeferred maintenanceImprovement ProposalsReview prior suggestions

WASTE ELIMINATIONMGM*All identified waste items are marked with an red tagMachine tagged with errors and improved suggestions

5S SORT LISTMGM*Every tag refers to a 5S Sort listThink breakDo we have any examples of deferred maintenance in our plant?

Tag noItem descriptionSession taggedDateTagged byResponsibleDue date

QUESTION YOURSELF SEIRIMGM*Do you find items scattered at your place?Are any items left in disorganized way?Are all item sorted and kept in designated place?Are tools and stationeries properly sorted and stored?

STEP 2 SET IN ORDERMGM*Every tag refers to a 5S Sort list

MISSING LETTER ?MGM*Every tag refers to a 5S Sort list

WHY-SET IN ORDER?MGM*The purpose of Seiton set in order is that everything that we regularly use should have a convenient placementTools should be kept at the point of useNo bending to pickup or move materialsAlter flow paths to improve efficiency

PLACEMENTMGM*

EFFICIENT LAYOUT AND COLOR CODINGMGM*Make a drawing of the current situationBrainstorm to find an optimal layoutAgree the color codeMark the location(removable tapes preferred) of all objectsMove the equipments if necessary

QUESTION YOURSELF SEITON?MGM*Are passages and storages clearly indicated?Commonly used tools & stationeries separated from the seldom used?Are containers, boxes, materials and fire extinguishers stocked up properly?Are there grooves, cracks or bumps on the floor which hinder work or safely?

STEP 3 SHINY CLEANMGM*Next step in 5S is to carry out a Shiny clean event

SHINY CLEANMGM*To keep your area clean on a continuing basisClean all machines thoroughClean all equipments, fixtures, and toolsClean the floor, walls, cabinets, shelves etc.

WHY SEISO?MGM*To prevent the area from getting dirty in the first place, so we dont have to clean it up afterwardA clean workplace is indicative of a quality product and processDust and dirt cause potential health hazardsThings to remember :-Sweep/VacuumDust / Mop

GUIDELINES SEISO?MGM*Divide areas into zonesDefine responsibilities for cleaningTools and equipment must be owned by an individualFocus on removing the need to clean

QUESTION YOURSELF SEISO?MGM*Are machines and equipments dirty?Are pipes dirty and corroded?Are nozzles dirtied by lubricants and ink?Are shades, lights, bulbs, and light reflectors dirty?

STEP 4 STANDARDIZED CLEANUPMGM*Continue sorting, storing and cleaning to maintain serene atmosphere at all times

WHY SEIKETSU?MGM*Prevents regression back to an unclean/disorganized environmentThings to remember :-Develop schedules, checklistsPeriodically evaluate area using 5S Audit sheetContinually improve neatness

PHASES OF SEIKETSU?MGM*Clarification of vital points for management Things to remember :-What are the minute defects?Basic conditions: Cleanliness, refueling, replace tightly bind fast, dirt, loosenessOperating conditions: pressure, temperature, time, flow volume, weight, Equipment, jigs and tools, sub-materials

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PHASES OF SEIKETSU?MGM*Prepare standards for the conditionsObjectification of judgment standards for normal versus abnormalJudgment without using measurement, knowledge, intuition and knack2

PHASES OF SEIKETSU?MGM*Judgment standards for abnormalitiesInspection methods that can be used by anybodyMethods for actions against abnormalities

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QUESTION YOURSELF SEIKETSU?MGM*Are there sufficient light?Is there noise/light in your place causing discomfort?Do people work at designated way?Is there any leakage?

STEP 5 - SHITSUKEMGM*

SHITSUKEMGM*To maintain discipline, we need to practice and repeat until it becomes a way of life

SHITSUKEMGM*Make sure you stick to standard procedures and make them a habit Be disciplined to follow rules and regulations to maintain standards

WHY SHITSUKE?MGM*To build housekeeping into every day processMakes the 7 wastes visibleGets everyone involvedThings to remember :-Training everyone is vitalInvolvement from all is necessary Commitment and discipline toward housekeeping is essential in taking the first step in being World Class5 S RATING0= Poor (Unacceptable)2= Satisfactory4= Excellent ( World Class Environment)

QUESTION YOURSELF SHITSUKE?MGM*If 4S done?Are regular 5s check conducted?Do people involved without reminder?Do assemble at time?

ACTION PLAN FOR IMPLEMENTING 5SAwareness programme of 5s for all employees, supervisors, engineers and managers.Form steering committeeApplication programme on 5S for all EmployeesSteering committee periodically evaluates all cells, scores displayed on the display boardDisplay posters on house keeping, distribute cards on 5S to all employeesAnnual award for the best cellMGM*

ADVANTAGES OF 5SIf tools and materials are conveniently located in uncluttered work areasOperators spend less time looking for items This leads to higher workstation efficiency, a fundamental goal in mass production A clean and tidy workplace leads to greater well being and increased motivationCompany image improvesTime saving Quick retrievalAccidents & mistakes minimizedIncreases spaceCreates workplace ownershipFoundation of all qc toolsContinuous quality improvementLean manufacturingVisual management systemResults in a place easier to manageSmooth working no obstructionMGM*

CHECKING SYSTEMMGM*

5S AUDITMGM*Three purposes of conducting regular 5S Audit reviews are:

Review compliance to the 5S standards for your factoryNote and address non-compliance to fix what is wrong!Provide a formal opportunity to suggest improvements

THE BASIC STEPSMGM*Plan for the audit by dividing the workplace into various areas, probably the same ones where different teams conducted the various 5S stages. Make a checklist for each area, based on the standards that were set during 5S.Find out the list of known problems in each area. From the initial 5S sweep, this may include:Machines needing repairTool racksSignage on tool racks or cabinets or storage shelves; warning signs; keep clear markings for corridors; or instruction pagesSurplus equipment or materials which were not immediately removed

DURING THE AUDIT, THREE KEY TASKSMGM*ONEDetermine whether known problems have been addressed: Does this machine still leak lubricants?Has the required tool rack been installed in this area? Is it labeled? Is it full? Are tools still left on workbenches?Is the warning sign in place so people will not walk under this crane?Why is this outdated drill press still in the corner?

DURING THE AUDIT, THREE KEY TASKSMGM*TWOSee that standards are being met: Are tools left on workbenches?Is something missing from a tool rack?Is dirt accumulating somewhere?Are existing labels still visible and easily read? (This is especially important for signs that may be obscured by dust, and for lines painted on floors where they can be scuffed)Are there new sounds or smells that indicate that gears are grinding or fluids are leaking?

DURING THE AUDIT, THREE KEY TASKSMGM*THREENote what has not yet been standardized this is the most creative and difficult part, because it may involve seeing what is missing in an area that seems tidy: Why is there no sign over the neat stack of work-in-process materials on that shelf? (How will the next shift know what is there, or what should go there?)Tools that are not yet labeledIs there a limit to how high those barrels can be stacked? Why dont we show that information on the sign for that storage area?Do we need all those cans of wing nuts in this assembly area? How many are used in one day? Should the rest of the months supply be stored elsewhere?

SAFETY INFRACTIONS SHOULD ALSO BE PART OF THE 5S AUDITMGM*

Are WHMIS (Workplace Hazardous Materials Information System) labels used properly?Are fire exits visible and clear? Are the fire extinguishers charged and inspected on schedule?Are stairs and ladders safe?Do we notice unsafe behavior regarding heights and falls? Climbing a ladder without maintaining three points of contact? Working on a height without the required safety tether?

TO FOLLOW UP ON EACH 5S AUDITMGM*Write up a work order to deal with each deficiencyUpdate the next check list:Check off what was correctedAdd new deficiencies to be reviewedDetermine the score:Deduct for each deficiencyAdd a point for each correctionAdd a point for each suggestion for improvementIf the previous audit had found deficiencies, the goal is to eradicate themThe ultimate goal is to regularly achieve zero outstanding deficiencies

HOW OFTEN SHOULD AUDITS BE PERFORMED?MGM*Regular audits lead to the best results:Weekly self-check audits by teams of workers, reviewing their own areasThis might be the best way to generate suggestions for improvementsMonthly audits by the area supervisorEnsure that the weekly audits catch any problems with the daily or weekly cleanupsPay special attention to the less-frequent cleaning tasksTry to notice what is missing: new tools that do not yet have a place in a rack; materials stored neatly but not well-labeled

HOW OFTEN SHOULD AUDITS BE PERFORMED?MGM*Quarterly audits by the plant managerEnsure that standards are being metIf there are deficiencies, ask why: try to determine the root causesEnsure that resources are allocated to repairs and to making the long-term improvementsWithout audits, it is impossible to ensure compliance.

5S AUDIT CHECK SHEETMGM*Model follows

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Prepared byM.Ganesh Murugan9715447621MGM*

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