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CONTENTS
INTRODUCTION ................................................................................1
5S BENEFITS.....................................................................................3
WHATS 5S?...................................................................................4
SORT (ORGANAZATION) ............................................................................. 4
STABILIZE (ORDERLINESS) ........................................................................ 5
SHINE (CLEANLINESS)..................................................................................5
STANDARDIZE (ADHERENCE) ...................................................................... 6
SUSTAIN (SELF-DISCIPLINE) ........................................................................6
5S IMPREMENTATION PROCEDURE ..............................................7
1. CURRENT SITUATION ANALYSIS ............................................................ 8
...............................................................................................10
2. IMPLEMENTATION OF SPECIAL 4S............................................................ 11
Sort .............................................................................................................11
Shine...........................................................................................................12
Stabilize.......................................................................................................13
Standardize .................................................................................................14
Bad and improved situation after special 4S ............................................... 15
3. IMPLEMENTATION OF SUSTAIN .......................................................... 16
4. When the activities do not work well ........................................................ 18
AT THE END OF THE TEXT ..............................................................19
Appendix
Situation Analysis Exercise Situation Analysis & Review Sheet (Service)
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INTRODUCTION
You could be knowing about "5S" already? And 5S activities would have been introducedat some dealers.
In this course, you would learn the meaning and activity of 5S. Later, by carrying out 5Sactivities at dealer, you can experience the approach involved, process to be followed andsee the result of your activity.These 5S activities not only have an effect at the work place (work environment, efficiency,
productivity, safety etc.) but also could create a positive influence in your personnel life.
It is pertinent to remember that 5S is not a one time affair, but a continuous and dailyactivity that is fundamental to every improvement activity.
What do you think?
Please write down what you felt?
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What do you think?
What are attributes that you find in photograph 'C & D', when compared to' A & B'
Please write down what you felt?
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5S BENEFITS
Effective implementation of 5S activities could produce the following benefits:
1. Lower operation cost (business running cost)2. Improve safety level of your workshop3. Lower your inventory (slow or dead stock), less waste4. Improve your customer satisfaction rate5. Improve service performance6. Improve teamwork and co-operation
Also lead to
Service Personnel feels
Clean! Easy to perform
Safety!
Comfortable Work effectively
CSimprovement
Reduce waste time
Dealer achieves
Better performance Team-work
Problem solvingmethod
Reduceinventory
ResponsibilityBetter workingcircumstance
Through 5S Activity you can expect
Improve cost
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WHATS 5S?
"5S" represents the '5Priciples', beginning with the letter S
Sort : Organization
Stabilize : Orderliness
Shine : Cleanliness
Standardize : Adherence
Sustain : Self-discipline
1. Sort: Organization
Differentiate the useful from the useless
Distinguish between required and not-required Eliminate all unnecessary items in the dealership
(workshop / warehouse / service receptions / showroom) Take picture before major cleaning is started
W/MUseful
Useless
SORT
Obsolete
Updated
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4. Standardize : Adherence
Establish operational rules Not return to the bad old ways
Visualize the factory (like marking and coloring) Establish internal rules to maintain the good environment
5. Sustain : Self-discipline
Make schemes to let all members follow the rules and continue the activity
Daily 5S create concrete time for 5S activities every day Achieve target by following the given standards Develop new standards Create PRIDE in the work place and maintain good working environment
- 5S award, 5S notice board, group activity
SUSTAIN
5STIME !
Make rules!
5S notice board
! 5S
5S awardDaily 5S
STANDARDIZE
5S
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5S IMPLEMENTATION PROCEDURE
5S by itself is easy to understand and is important in creating a healthy, efficient and safework environment. Also the program could have positive influence on other dealer activities.
But how would you start 5S activity in your dealer?In this chapter, you can learn how to introduce and implement 5S activities effectively in
your dealer.
Continuous and evolving activities
Implementation of Special 4S
Sort Shine
Stabilize Standardize
Implementation of Sustain
Current Situation Analysis
Activities of wholemembers in
dealer
Before
After
After
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1. Current Situation Analysis
When starting 5S activity, you would review current 5S situation in the workshop andclearly identify problem areas.
- Review current situation according to the 5S situation Analysis & Review material.(Refer to appendix)
- Take pictures of poorly kept / maintained/ managed area(s).- Review the result of 5S situation analysis including pictures, and decide the targetarea(s).
- Review the current situation strictly from customer point of view.
Customer pointof view
Take pictures of bad areas
Review current situation
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Sample of 5S Situation Analysis & Review Sheet(In the end of the text, you can find whole review sheet.)
Analysis & Review check-sheet covers all most all of the 'Service facility & activity areas',
including appearance of service staff, HSE etc. (HSE: Health Safety & Environment)
Facility & Service personnelsAppearance
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Following are the features of check-items, listed in the 'Analysis & Review sheet'.On analysis, you can find that all the check-items when implemented well, leads to certain
benefit, as explained in page - 5.
Customer point of view Easy to find?Easy to use?Good / Excellent appearance?Clean?Orderly?Up-dated material?Only necessary things are found?Safe?
Safety Avoid hazard?Not Slippery?Adequate illumination?
Quality Possibility of getting scratch?Use of protectors?
Productivity Easy to work?Easy to retrieve / return?Shortened Time?Easy to find?
Each area is; dedicated / marked / labeled?
Rules Everyone knows?Responsible person available?Frequency?Constancy?Availability of standard and record?
- Situation Analysis
Using Situation Analysis & Review Sheet (See appendix), evaluate your own dealer.
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2. Implementation of Special 4S
Special 4S days: Implement the 4S activities (Sort, Shine, Stabilize, and Standardize) ata time, as a starting event of 5S activities.
Remember the meaning of each "S" and experience the qualitative change realized interms of; cleanliness, orderliness, convenience, safety etc.
Differentiate the useful from the useless
Items left in the dealer are all necessary and inventory is reduced
(1) Differentiate the useful from the useless Identify unnecessary items at each target area by discussion and collective
decision. If therere tools and equipment items which can not be classified immediately,
make a list of questionable objects
Sort
Shine
Stabilize
Standardize
Organization
Cleanliness
Orderliness
Adherence
Sort
Useful Useless Questionable
Useful?
Useful!! Useless! Questionable!
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(2) Eliminate all unnecessary items in the dealership(Workshop / warehouse / service receptions / showroom)
Clean all areas Make no compromise
- Clean and comfortable environment for both dealer personnel and customers- Improved safety level- Easy to discover trouble or damage on any items and helps in maintenance.- Avoid things getting dirty, so that frequent cleaning-up is not required.
(1) Clear the target areas of all the items that could be moved out.
(2) Cleanse the facility, lifts, tools etc. completely using appropriate cleaner & tools.
(3) Discover the source of dirt and get rid of it.(4) If necessary, paint the walls, floors, lift etc.
Discover the trouble or damage of the items during cleaning.
Shine
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Create a place for everything and put everything in its place
- Items are stored in good order- The efficiency in the dealer is improved (easy to take out, easy to put back)- Safety level is improved
(1) Decide on layout of zones in the warehouse / workshop
(2) Identify places for tools & equipment by white plastic tape tentatively and post label.(3) Find suitable storage and create functional storage system. (Easy to identify andretrieve)
Stabilize
Identified by whiteplastic tape
Name & labels
Functional Storage
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Establish operational rules Not return to the bad old ways
- Everyone can understand the rules and 5S activities are continued
(1) Establish visual operational rules. (Everyone can understand the rule; location of
rooms, tools & equipment.)
(2) Make 5S operation rule and decide staff / team in charge of each area formaintenance and review.
Appropriate '5S administration' should to be established to ensure that thestandards are sustained and objectives' of continuous improvement is realized.
Ex.- Establish Operation rule Decide cleaning and reviewing responsible and its cycle Make cleaning and reviewing result sheet for each area Maintenance check sheet for tools and equipment
- Set 5S day Polish up day Disposal day
Standardize
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Before and Improved after special 4S.
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3. Implementation of Sustain
Through Special 4S activity, you and dealer staff could realize good work environment,well defined rules have been made, more suggestions' regarding improvements are being
received and could build excellent team spirit.
Final Step: "Sustain", Implement a comprehensive 5S administration to ensure that theprogram and activity is continued in a well defined manner, in order to sustain standardand realize continuous improvement.
To implement 4S (Sort, Shine, Stabilize and Standardize) firmly and to practice it on adaily basis, eventually to realize that as a work-culture at the dealer.
- Continuous improvements of dealer facilities- Improved morale- Improved internal communication in the dealer- Motivated dealer- Strengthen the team spirit
There are various activities relevant to the stage "Sustain". So you may choose the most
appropriate ones, pertain to your respective situation and progress made.
- To maintain the activity
Set standardsStandards such as : Avoid making dirt in order not to have to clean up When you made something dirt, clean it immediately Put tool back at its place, after you use it. When you produced trash, put it into garbage can immediately etc.
5S is ourwork-culture!
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Set daily 5S timeTo implement the daily 5S, it is important to set daily 5S time (for example, set5S time at 9:00 to 9:15 in the morning). This means following two things. Dealer Management emphasizing their due commitment towards 5S
activities. Make the dealer personnel recognize and implement 5S activity as
personnels duty
Group ActivitiesAs it may be the first time for personnel to do daily 5S activity, they may confuseas what to do to improve working environment. So it is effective to organizegroups and implement daily 5S activity. Group activities also improveinter-personnel communication and strengthen the team spirit.
Assign a zone / responsible area
Assign a zone / responsible area to each group. This will generate the dutyconsciousness among personnel.
Group meeting It is practical to hold a group meeting at daily 5S time. Review the activities and discuss how to progress the activities, how to
solve problems, schedule, share of work with all group members. It isimportant that decision made during these meetings should be collective.
Dealer Management participation is recommended in these meetings, asthat will reflect their interest in the 5S program and could motivate all staff.
Layout of workshop
Reception andshowroom
Group responsible
Chart of 5S area
Tools &Equipment
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4. When the activities do not work well
Messiness could be found everywhere From where should we start?
After the 4S activities, our dealer was back to bad old days.
No time and space for 5S activities in dealer
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AT THE END OF THIS TEXT
Remember 5S benefits again.
1. Lower operation cost (business running cost)2. Improve safety level of your workshop3. Lower your inventory (slow or dead stock), less waste4. Improve your customer satisfaction rate5. Improve service performance6. Improve teamwork and co-operation
When you have finished this course, you would have gained better understanding of thesebenefits than you would have known at the beginning.
Also you would know the inherent meaning that 5S represents.
Sort : Organization
Stabilize : Orderliness
Shine : Cleanliness
Standardize : Adherence
Sustain : Self-discipline
Imagine what you could do, after you have returned to your work place?Probably it is obvious you know that already!
If your dealer is already in to 5S activities, your focus could be on accelerating the programor making a qualitative difference by own activity as the situation warrants.
5 S
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Service Reception & Counter
Entrance of service reception
Business hour8:00 17:00
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Customer Parking
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