‘5S’ METHOD OF WORK PLACE

ORGANIZATION AND VISUAL CONTROLS

Popularized by Hiroyuki Hirano (1990). The origin is rooted in the works of two American pioneers Frederick W. Taylor and Henry Ford – Studied by Japanese

managers.

‘5S’ – Each ‘S’ means.,• SEIRI – Sort - Clearing• SEITON – Set - Organizing• SEISO – Shine – Cleaning• SEIKETSU –Standardizing• SHITSUKE – Sustain – Self

Discipline and Training

COMMON MIND SETS…

• Its an additional burden. Too busy to do 5S activities.

• Why clean it? It will get dirty again

• We cannot change the existing setup.

• More work pressure – No time for these things

COMMON MIND SETS…

• Expensive – Why to waste money?

• We are comfortable – Why to change?

• It will take time.

But the winning companies says…• Work efficiency enhanced due to

organized work place • Achieve remarkable cost reduction in

production process and improved productivity by 20%

But the winning companies says…• Promotes safe, healthy and beautiful

work environment • From the bottom of the list we become

the number two profit maker • Waste elimination, Cycle time reduction,

Space generation, Inventory reduction and improved work ethics

But the winning companies says…• World class companies do

not succeed, it’s people who do

So,What’s good in it?

‘5S’• SEIRI – Sort - Clearing• SEITON – Set - Organizing• SEISO – Shine – Cleaning• SEIKETSU –Standardizing• SHITSUKE – Sustain – Self

Discipline and Training

1S – SORT - Clearing“…only what is needed, in the

amounts necessary, as they are required…”

Eliminate unwanted items from your work

area

SORT – Fights with Habits

SORT – Fights with Habits

• It is difficult and confusing to decide which would be wanted in future.

• People tend to keep extras or duplicates “just in case a need comes in future”

• People do not realize the importance of space, believing in unlimited space availability.

JUST-IN-CASE JUST-IN-TIME

A Simple Flow chart

What is unwanted?1. Parts & Work in Process (WIP)• Things fallen back behind the machine • Extra WIP• Stock of rejected items• Items accumulated over period for rework• Material awaiting disposal decision• Material brought for some trial, still lying even

after trial• Small qty of material no longer in use

2. Tools, Toolings, Measuring devices• Old jigs, tools not in use • Broken tools, bits, etc. • Measuring equipment not required for the operation being performed 3. Shelves and Lockers• Shelves and lockers tends to collect things that nobody ever uses , like surplus, broken items etc.4. Passages and Corners• Dust, material not required seem to gather in corner

What is unwanted?

5. Besides Pillars, Floors• These places tends to collect junk.6. Walls and Boards• Old out dated notices which have lost their relevance• Dust, remains of torn notices, cello tape piece

What is unwanted?

What is unknown?

• Simple – • Unable to decide whether it is useful or

not.• Good material – Not useful to you. May be

of use to somebody else.

SEIRI = SEIRI = SortingSorting

Activity Establish a criteria for eliminating unwanted itemsEliminate unwanted items either by disposing

them or by relocating them.

Meaning Distinguish between necessary and unnecessary items and eliminate the

unnecessary items

Success Area saved or percentage of space availableIndicator

INTERACTIVE BIT

Give me three examples of areas that could benefit from sorting

SEITON – SET - ORGANIZING

• “A place for everything and everything in its place”

• Identify and allocate a place for all the materials needed for your work.

• Decide where things belong.• Decide how things should put

away• Obey the put away rules

SEITON – SET - ORGANIZING

SEITON – EXAMPLE

SEITON = SEITON = SET-ORGANIZINGSET-ORGANIZING

Activity - Functional storage - Creating place for everything and putting everything in its place

Meaning To determine type of storage and layout that will ensure easy accessibility for everyone .

Success - Time saved in searching Indicator - Time saved in material handling

INTERACTIVE BIT

Discuss two areas where production is frustrating

• Do the tools keep going missing, or do you have to wait for them to become available.

• Do operators zig-zag around the area and/or get in each others way

• Do we have Mix Ups?

•

SEISO – SHINE - CLEANING

• Here cleaning means more than just keeping things clean – Its for your safe.

• At least 5 minutes everyday for cleaning

SEISO-SHINE-CLEANINGSEISO-SHINE-CLEANING

Activity - Keep workplace spotlessly clean- Inspection while cleaning- Finding minor problems with cleaning inspection

Meaning Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of Inspection.

Success - Reduction in machine down time Indicator - Reduction in no. of accidents

INTERACTIVE BIT

What areas of the factoryare the dirtiest and/or aredepressing to work in?

SEIKETSU - STANDARDIZING

• Regularising 5S activities by putting systems in place – Everyone does things the same way

• Make it easy for everyone to identify the state of normal or abnormal condition.

• For maintaining previous 3S, use visual management

5S IS EASY TO DO ONCE – CONSISTENCY IS DIFFICULT

SEIKETSU - STANDARDIZINGSEIKETSU - STANDARDIZING

Activity - Innovative visual management- Colour coding- Early detection of problem and early action

Meaning Setting up standards / Norms for a neat, clean,workplace and details of

how to maintain the norm (Procedure)

Success Increase in 5S indicatorIndicator

• Make ‘5S’ is a HABIT• Without this, the time involved

in all the other S will be in vain.

SHITSUKE – SUSTAIN – SELF DISCIPLINE & TRAINING

• We need Everyone to maintain 5S guidelines.

• To maintain discipline, we need to practice and repeat until it becomes way of life.

• Discipline is the core of 5S

SHITSUKE – SUSTAIN – SELF DISCIPLINE & TRAINING

SHITSUKE – SUSTAIN – SELF DISCIPLINE &

TRAINING• Commitment + Everyone’s Involvement = Success to 5S

SHITSUKE-SUSTAINSHITSUKE-SUSTAIN

Activity - Participation of everyone in developing good habits

- Regular audits and aiming for higher level

Meaning Every one sticks to the rule and makes it a habit

Success High employee moraleIndicator Involvement of all people

SOME COMPARISONSBEFORE 5S AFTER 5S

The rules…

• Remove fixed ideas.• Think of ways to make it possible.• No excuses needed.• Go for the simple solution, not the perfect one.• Correct mistakes right away.• Repeat ‘Why’ 5 times.• Ask ideas from many people.• There is no end to improvement.

BENEFITS Reduced set-up times Reduced cycle times Reduce searching time Increased floor space Lower safety incident/accident rate Less wasted labor Better equipment reliability Higher Quality Lower cost Reliable Delivery

Roles and Responsibility• Leaders must set the tone and lead by

example. • We should commit to the initiative,

Provide time to the workforce to develop and implement 5S changes.

• Any implementation should have a drive.• Conduct short, focussed and frequent

communication sessions.• Select areas that needs 5S – as pilot areas• Share the successes

It’s a start….