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Which is look good?5S

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Which is look good?5S

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Need more photographs?5S

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Which is look good?And now think why bottom picture look good?5S

Pankaj - Paramount6History of 5S

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Pankaj - Paramount8Why Implement 5S?12) Improves quality11) Improves job preparation times10) Improves productivity9) Improves safety hazards are out of place8) Reduces inventory and supply costs7) Recapture valuable floor space6) Contributes to how we feel about our product, our company, and ourselves5) Make your plant customer ready at all time4) Help participants to see changes as something positive and even fun3) First step to reducing waste2) You can achieve a competitive advantage.1) It can be done today!

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Age

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Pankaj - Paramount15Sr. No.Action1Standardize frequency of segregation2Only items that will be used today will be on the shop floor/Table or work place. Others are in its identified location3List of records/retention period for records. Keep records of things thrown away.4Scrap sorted/categorized5Dispose unneeded items by either distributing to others who need or as per norms. Place undecided items in the Red tag area.6Dispose out of date notices/calender/displays7Record specific benefits achieved on implementation of 5S practise.

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Frequency of useStorage Method*Things you have not used in the past one yearThrow them out*Things you have used once in the last 6-12 months Store at distance OR Keep in store

LOW*Things you have used only once in the last 2-6 months Store it in central place in your zone*Things used more than once a month Store it in central place in your zone

AVERAGE

HIGH*Things used once a week Store near the workplace*Things used daily or hourly Store near the workplace

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Pankaj - Paramount17Allocate a central "Red Tag Area" where items go that cannot be simply thrown in the trash.Include disposal instructions if necessary.Appoint a review board for questionable items. (You may not need it but someone else may.)Allocate a "Yellow Tag" location near the workplace.Review on a specific date.Store occasionally necessary items in out of the way locations.Leave "Green Tag" items in the workplace.Set their final location later.

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Pankaj - Paramount19Seiri = Sorting Identifying Unnecessary

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Pankaj - Paramount22Seiri = Sorting Audit Check ListSr. No.Check PointsSystemResultMax. MarksMarks ObtainedRemarks1Standardized frequency of segregation2Disposal of segregation with respect to re-usa ble, potentially useful, special done or not3List of records/retention period for records4Scrap sorted/categorized & Records of Scrap5

Pankaj - Paramount23 Stage : II Seiton = Systematic Arrangement

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Pankaj - Paramount27Seiton = Systematic Arrangement USE : 1 ) Signboards

2) Colour codes

3) Outline markings

4) Labels 5) Racks,Area,Crates,Cupboard,Partition,Bags etc.

Pankaj - Paramount28Seiton = Systematic Arrangement

Functional Storage

Pankaj - Paramount29Seiton = Systematic Arrangement Store frequently used material near the workplace and less frequently at some distanceUsage FrequencyWeight & Shape of theMaterial Heavy material should be stored at lower levels/layers place directly on the material handling device for ease of handlingCategory Same category of material may be stored in one location. Eg. Allen Screws, Oil Seals, Same Raw MaterialsOperation Wise All items required for an operation may be stored in one location. Eg. Allen key, spanner etc hand tools required for setting m/c

Pankaj - Paramount30Seiton = Systematic Arrangement Outlining and Placement Marks - Mark boundaries of dept. aisles, Machines - Follow straight line, right angle rule - Nothing shall be kept outside the boundaries Stands and shelves - Keep only required number of stands and shelves - Standardize height, size & weight - Provide casters where necessary so that it can be movedWires and Ducts - Colour code - When there are multiple connections - bundle the wires, label them and make sure that they are in straight line /right angle and firmly anchored Machine-tools & Tools - Put the tools in the order you need them - Location of the tool should be such that it can be put away with one hand - Try to eliminate some hand tools by permanently attaching it to the bolt head

Pankaj - Paramount31 Blades, Dies, Other important consumables - Store them in the protected place - Maintain these things regularly by applying rust preventive, oiling etc. WIP- Work In Process - Designate a place for each component/part - Decide on how much quantity to be stored - Ensure that there is no damage to good part during transit, they do not get rusty and they are not mislabeledSeiton = Systematic Arrangement Oils & Grease - Reduce number of oils & Grease used (Standardize) - Colour code for oil & Grease - Safety aspects - fire prevention, pollution, Prevent leakage, spillage Instrumentation & Measuring Devices - Label them, show direction of flow (SOP)

Pankaj - Paramount32Seiton = Systematic Arrangement Audit Check List Sr. No.Check PointsSystemResultMax. MarksMarks ObtainedRemarks1Prefixed number of Items, Location for items & items have location names2Accessibility of items, proper stacking & shelf stratification3Categorization of storage based on frequency of use4Work place lay out5Visual Management6Display of preventive maintenance/sorting/cleanning schedules7Space saved for implementing Set in Order

Pankaj - Paramount33 Stage : III Seiso = Cleaning Meaning : Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of InspectionActivity- Keep workplace spotlessly clean- Inspection while cleaning and after cleaning Continuously.- Finding minor problems with cleaning inspectionSuccess- Reduction in machine down timeIndicator - Reduction in no. of accidents Here cleaning means more than just keeping things clean. Cleaning should be viewed as a form of Visual Inspection

Preventive measures should be taken to tackle problems of dust, grim, burrs, leakage etc. Root cause of the problem should be identified and it should be eliminated

Pankaj - Paramount34 Seiso = Cleaning 10 Minutes Every day for cleaning

Devote 10 minutes everyday for cleaning your work area

Participation of everyone is required

Attack hard to clean places regularlyVarious Minor Defects= Trash= Dirt=Knocking = Loose parts= Leaks=Scattering=Skips=Curvature=Abrasion=Rust=Scratches=Eccentricity=Lurching=Abnormal Movements=Vibration =Abnormal Smell=Abnormal Sounds =Heat=Faded colour=Hisses

Pankaj - Paramount35 Seiso = Cleaning Grime, Clogging, Dust balls, Rust, Leakage, Paper, Velvet, Gum, Paper cutting, etc.No oil, Low oil, Leakage, Filter clogging, Dirty oil, dirty or bent oil lines, clogged drainage, oil spillage, worn & torn ports etc. Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc.Loose bolts, welding detachment, Loose parts, Vibration or bumping Noise, Friction Oil tanks, Motors, Fans, Heater, Axles, Control panels, washing/ cleaning water, Bearing, wiring etc. Compressed Air lines, Air valves, Connections, Meters, Filters, Reservoirs Breakage, Cracks, Dent on sliding parts, Handle has come off, Broken switches, Wire joints come off, wires are broken or crack, Crack dial of various pre. gauges, meters etc.Work Station, Work Tables, Chairs, Tube Lights, Fans, Switches, Computers, Printers, Files, Cupboard, Cabinet, Racks, Crates, Pallets, Bins, Glass, Partition, Windows, Doors etc.

Pankaj - Paramount36 Seiso = Cleaning Guideline for implementing Prepare one cleaning schedule and cover all items/locations under cleaning schedule Typical items include Table , Chair , Computer , Telephone , Printers, Jug, Glass, Cup , Fans, A/C, Fridge, Switch Box, Pipes, Fire Extinguishers etc. Typical locations include Floors, Walls, Windows, Pillars, Stairs, Toilets, Aisle, Notice boards, Displays, Security Cabins, Office Cabins, Factory Surroundings, Garden, Plants pots, Canteens, Tool Rooms, Scrap Yard etc.

Pankaj - Paramount37 Seiso = Cleaning Audit Check List Sr. No.Check PointsSystemResultMax. MarksMarks ObtainedRemarks1All items covered under cleaning schedule2Cleaning responsibility known3System of proper drainage4Machinery/Equipments/Furniture etc. Cleanliness5Work Place / Floors / Walls/Windows/Doors/Aisle/Partitions/Canteens/Cabins/Pillars/Stairs/Ceiling/Corners/Factory Surrounding etc. Clean & Maintains

Pankaj - Paramount38 Stage : IV Seiketsu = Standerdization Activity- Innovative visual management- Colour coding- Early detection of problem and early actionSuccess Indicator Increase in 5S indicatorTools used for analysis :MTTR = Mean Time To Repair MTBF = Mean Time Between FailuresOEE = Overall Equipment Effectiveness

Pankaj - Paramount39 Seiketsu = Standerdization Regularizing 5S activities so that abnormalities are revealed Make it easy for everyone to identify the state of normal or abnormal condition For maintaining previous 3S, deploy visual management It has been estimated by scientific study that 60% of all human activities starts with sight 5S is easy to do once. It is consistency that is difficult. That is why Visual Management is so important, so that everybody will know that there is some problem.What visual control communicates ?

It grabs one or more of our senses in order to Alert us to an abnormality Help us recover quickly Promote adherence and prevention Enable successful self management

Pankaj - Paramount40 Seiketsu = Standerdization Some methods for visual communication

Colour coding Use of Labels Danger alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators

Pankaj - Paramount41 Seiketsu = Standerdization Some methods for visual communication Labels Precision management labels Inspection labels Temperature labels Responsibility labels Skill Matrix board Photographs SOP Process Flow Chart Diagrams Sign Boards

Pankaj - Paramount42 Seiketsu = Standerdization Points to remember in making visual control tools :1. Make them easy to see from distance2. Put the display on the things 3. Everyone can tell what is right and what is wrong4. Anybody can follow them and make necessary corrections easily5. Work place should look brighter & orderly

Make Sorting, Set in Order, and shine as normal as brushing your teeth. Make it a habit. When you standardize, you create the rules, and enforce the rules. Many companies fail at this stage because company does not create and enforce the rules. 5S housekeeping is not a one time event. It is constantly on-going.

Pankaj - Paramount43 Seiketsu = Standerdization Audit Check List Sr. No.Check PonitsSystemResultMax. MarksMarks ObtainedReamrks1All items covered under cleaning schedule and records are maintains regularly.2Cleaning responsibility known and documented3Machineries/Equipments/Furnitures cleanliness and documented.4Work Place / Floors / Walls/Windows/Doors/Aisle/Partitions/Canteens/Cabins/Pillars/Stairs/Ceiling/Corners/Factory Surrounding etc. Clean, Maintains & properly documented.5Labels, Boards, Photographs , SOPs are their in respective areas or locations6Diagrams, Sign Boards, Flow Chart on respective areas or locations.7Boards, Displays, Photographs, Flow Charts, Labels can easy to see from distance.

Pankaj - Paramount44 Stage : V Shitsuke = Self Discipline Meaning : Every one sticks to the rule and makes it a habit Activity- Participation of everyone in developing good habits- Regular audits and aiming for higher levelSuccess Indicator - High employee morale - Involvement of all people Which Activities can be done 5S Committee5S Training5S Competition / evaluation5S MonthPosters , Literature etc.

Pankaj - Paramount45 Shitsuke = Self Discipline We need everyone to maintain 5S guidelines.

To maintain DISCIPLINE, we need to practice and repeat until itbecomes a way of life.

Discipline is the Core of 5SDiscipline means making a steady habit of properly maintaining correct procedure.

Time and effort involved in establishing proper arrangement and orderliness will be in vain if we do not have discipline to maintain it.

Pankaj - Paramount46 It shall be my constant effort to maintain my workplace in good order by Assigning a place for everything & keeping everything in its place Sorting out unwanted material periodically & discarding them Keeping my work area neat & clean everyday Shitsuke = Self Discipline 5S Pledge

Pankaj - Paramount47COMMUNICATIONInform people what you what to achieve5S campaign, Posters, Display boards, 5S Video, Discussion, Share/Benchmarks Practice.EDUCATIONTeach people how to apply 5SOrientation & TrainingREWARDSRecognize people for their effortReward individually, Group Certificates or other.TIMEAllow time to clean work area10 minutes before going home and starting work Clean work area.STRUCTUREIdentify what needs to be done, By whom and ensure schedule is updated and visible to all.Depute Tag Team, Sweep Team and 5S Committee.

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5S

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Pankaj - Paramount515SThank you and Best of luckEveryday is 5S day