Date post: | 06-Apr-2017 |
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“5-S METHODOLOGY”
• 5S is an approach originally developed in Japan for better house keeping. Now it is been utilized for keeping better work place.It includes 5 steps which are to be followed sequentially.
• Following Japanese terms collectively are as called 5S• 1S - Seiri or Sort • 2S - Seiton or Set In Order• 3S - Seiso or Shiny Clean up • 4S - Seiketsu or Standardize • 5S - Shitsuke or Sustain
• By Implementing 5S one will get to know how cleanliness, orderliness, safety practises and better work environment results in increased free space, higher yield and transparency in work.
REQUIREMENTS OF 5S• To implement 5S following are the requisites
1. Consciousness fora. Strong determinationb. Trainingc. Constant Efforts
2. Ability toa. Judge what is importantb. Attention to details
3. Continuous implementation through total employee participation and better communication
1ST ‘S’ – SEIRI OR SORT
Step 1 : Tagging the followinga. Not needed at allb. Needed But Not Nowc. Needed But Not Hered. Needed But Not So
Much QuantityStep 2 : Entry in Red tag Register Step 3 : Assign Red Tag area and dump the scrap
It aims at taking out unnecessary items and dumping it into garbage(i.e Red Tagging)
Action during Seiri
KEY INDICATORSIndicators of success1. Decrease in unnecessary items and reserved
stocks2. Reduction in sq.ft area consumed
Checklist – • Do you find items scattered in your workplace?• Are the boxes ,papers and other items left in a
disorganized manner?• Are there equipment and tools on the floor ?• Are all items sorted out and placed in designated
spots?• Are tools and stationary properly sorted and stored ?
RESULT FROM SEIRI
Created free space
2ND ‘S’ – SEITON OR SET IN ORDER
• It aims at arranging the necessary items in proper order so that they can be easily picked up for use• Steps for Seiton1.Systematic Arrangement is a form of
standardization2.3 Keys are the basic rules for Storage3.Fixing Position4.Fixing Quantity5.Signs for Storage of Work-in Progress
SYSTEMATIC ARRANGEMENT
KEYWORD 3 POINTS 3 KEYS
- Anybody - Immediately
1. Can see
2. Can take out
3. Can return
1. Where?.. Fix position
2. What? …Fix items
3. How many? Fix quantity
3 KEYS
It answers the question
What items are to be kept ,where and in how much quantity ?
RULES FOR STORAGE1.Search – Free2.Count – Free3.Air – Free4.Climb – Free5.Bend – Free6.First – In, First – Out7.Heavy/ Tall Things On Bottom Shelves8.Fast Moving Materials Close To Point-of-use/ Point-of-
issue9.Adequate Lighting10.Adequate Ventilation
Street numbers
Address of bin:A32=Block A, Street 3, House 2
House numbers
Block tables
Fixing Position
TOOLS• For Eg. Colour coding for files/tools, tool
organizer to organize tools, shelf colour/tagging etc.• The purpose of 5S Seiton is to find a place for
everything within your working area, everything should be located as close as possible to where it is needed and at a location that is both safe and easily reached• Following are few eg.
EXAMPLES
Before After
Seiton for Store
Make your Store:• Search free• Air free• Climb/Bend free• Count free• FIFO
• Warehouse is where material is dumped in any quantity.• Store has Reserved Seats.
Two-Bin System
Kanban card
When bin is empty, card is placed here, to be picked up periodically by Purchase
Seiton
SEITONSuccess Indicator• Reduction in handling/searching timeChecklist• Are passage ways and storage places clearly
indicated?• Are commonly used tools and stationery
separated from those seldom used?• Are containers and boxes stacked up properly?• Are fire extinguishers and hydrants readily
accessible?• Are there grooves, cracks or bumps on the floor
which hinder work or safety?
3RD ‘S’- SEISO OR SHINY CLEAN UP 1/2
• Clean your workplace so that there is no dust. In workplace, it becomes easy to trace leaks, cracks etc.• This stage has two goals:1. Determine and gain agreement on the
desired level of cleanliness2. Learn how to make new routines so this will
become standardized (in the Seiketsu stage)• Several questions help this stage to be more than
just "polish until it shines for inspection":a. How much cleanliness is required for safety,
for ease of use, and to minimize equipment breakdown?
b. How clean should the environment be for comfort and morale?
SEISO 2/2c. How will cleanliness improve product
quality?d. While cleaning, do we notice maintenance
issues that should be addressed?
1. Surroundings2. Equipment3. Storage Areas
Cleaning Targets
Surroundings : What to Clean ?
1. Are there any unnecessary items around you ?
2. Are all files & folders immediately accessible ?
3. Is cleaning done every morning ?4. Is clearing up done every day
after work ?
Maintaining A Spotless Workplace
Example of ‘3S’
Factory Surroundings
FACTORY ENTRANCE SCRAP YARD
Front area and Scrap yard are comparable
SEITONIndicators of Success• Reduction in machine downtime• Increased life of machine parts• Reduction in number of accidents• Reduction in rejection/reworkChecklist• Are the floor surfaces dirty ?• Are machines and equipment dirty?• Are wires and pipes dirty or stained?• Are machine nozzles dirtied by lubricants and ink ?• Are shades, light bulb and light reflectors dirty?
4TH ‘S’- SEIKETSU OR STANDARDIZE
• This phase draws on the notes from the Seiso stage• A practical target is to have all workers
take five minutes every day to tidy up after themselves including the time to complete and sign the checklists• By dividing the work among all the
employees:a. No-one has a huge burdenb. No-one seems unproductivec. Morale improves because everyone has a
common purposed. Supervisors should monitor compliance with
Seiketsu. The checklists make this both important and achievable.
What Is To Be Standardised
• Workstation layout, work area layouts.• Work in Process (WIP).• Sequence of work.• Cycle time of work .• Material and tools used.• Machines and their process parameters.• Quality parameters, methods of measurement,
reaction plan and reporting method. • “ What, Where, When, Who & How ” of work .
METHODOLOGY TO PRACTICE ‘4S’
• Preparation of S.O.P.( Standard Operating Procedure) for all the activities to be carried out to maintain 1S,2S, & 3S.
• Following areas shall be covered while preparing S.O.P. : • Machine & Equipment maintenance.• Manufacturing Processes maintenance.• Work Place maintenance.• Quality Standards and Procedures maintenance.
SEIKETSUIndicators of Success• Number of areas/cover made transparent• Number of new problems exposed & solvedChecklist • Is the standardization system company-wide ?• Is the setting, revision , and abolition of
standards encouraged ?• Have official procedures been laid down for
setting, revising, and abolishing standards ?• Is accumulation of technology promoted ?• Are standards being utilized ?• Are standards up to-date and capable of being
put into practice
5TH ‘S’- SHITSUKE OR SUSTAIN 1/2
• Clear deliverables & communication.• Score Keeping• Continuous improvement
with cyclic mini-5S events.
Tools:• Training and Awareness of
5S• Dedicated 5S team• Clear 5S Map and
Responsibilities/Ownership.
SHITSUKE• Indicators of success• High Employee morale• Involvement of people in the movement• Checklist • Are regular 5S checks conducted?• Do people clean without reminder?• Do people follow rules & instructions?• Do people wear their uniforms & safety gear
properly?• Do people assemble on time?
THANK YOU