5s the Secret to Japnese Sucess

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THE SECRET TO

JAPANESE SUCCESS

5S

KARAN GARG

100903043



DISCOVERY OF 5S

Thirty years ago researchers startedstudying the secret of success of Japanese manufacturing companies5S turned out to be the mostimpressive "secret"

The factories were so well organizedthat abnormal situations were readilyapparent



Equipments were so clean and wellmaintained that any problem such as aloose bolt or leaking oil could be easilyseen.This passion of cleanliness and

orderliness became a hallmark of Japanese organizations.



What is 5What is 5--S : S :--

5S is a Japanese word meansHousekeeping.5S is a basic technique to enhancethe workplace appearance and givea pleasant work environment.5S is short for: Sort, Set in Order ,Shine , Standardize and Sustain.





LIFE W ITH OU T 5LIFE W ITH OU T 5--S :S :--



R equirements to implement 5S

5S is one of the activities that will help ensure

our company¶s survival.H elps Create a Better Working E nvironmentand a Consistently H igh Quality Process.Results I n a Place E asier to Manage, Smooth

Working, NO OB T RUC TI ON, NO D EVIATI ON, NO PROB LE MS.



THE NEE D O F A "5S³ S T R ATEGY

QU ALITY

PRICE

FLEXIBILITY

DELIVERY SERVICE



1 S 1 S--SEIRI SEIRI : :-- ( Sor t ing, Cle a ring)( Sor t ing, Cle a ring)

SEI R I is distinguishing or sorting outbetween wanted and unwanted items in aplace and removal of the unwantedDecide what you needRemoval of items that are not needed

I dentify needed & unneeded inventoryI tems which are not needed currently in use

should be stored in appropriate location



A ll unneeded tools, parts should be removed from the

area

before after



SEIRI - all unneeded things should be kept in one place



- Before

After -



2 s2 s--SEITON SEITON: :--( S tab ilize ,Orderliness)( S tab ilize ,Orderliness)

A Place for everything and everything in its placeWell defined place for tools & equipment.

I tems should be arrange in a way that can be easily return to their place.A ll cabinets & containers should be labeled.A rea should be organized that productionmaximized.Know what, where and how to set items in proper order .



Well defined place for tools & equipment .



Before -

- After





3 S 3 S--SEISO SEISO : :-- ( Cle a nliness, S h ining)( Cle a nliness, S h ining)

Sweep your workplace thoroughly so that there isno dust anywhere.

T ools and machineries is kept clean and in proper workingorder ; so that it is always ready to use.Maintaining cleanliness should be part of daily work itshould not be occasionally activity, initiated when thingsget to messy.Customers are impressed with a clean environment .

I t improves morale of employees .









After

Before



4 S 4 S--SEIKETSU SEIKETSU: :--(S ta nd a rdizing)(S ta nd a rdizing)

Standardizing all the 5S activities throughout theorganization.

Be consistent and standardize fashion.Keep up the first 3-S.I ntroduction of the methods to maintain

standard.Best current practice.F ollow some standard like I SO.



5s5s--SHITSUKI SHITSUKI: :--(Susta

ining discipline )(Susta

ining discipline )M easure, M aintain & Continuously

improve the 5S activities.

F ollow safety procedure at all time.Use and follow standard procedure.Be aware of own attitudes and habits,

they affects other more then you know.F ollow company rules and regulations.



L ife with 5S«..



B enefi t s : B enefi t s :--

F or employees :1. Makes job satisfy and enjoyable2. Removes obstacles.3. I ncrease efficiency and effectiveness.4. E ducate co-workers.5. I mprove morale.6. Provides role and responsibility.



B enefi t s : B enefi t s :--

F or company

1. L ower cost and higher quality.2. L ess safety concerns.3. I mproves customer satisfaction.

4.E

fficiency and effectiveness increase.



Company follow 5Company follow 5- -S :S :--

HP Toyota

H arley DavidsonP arle-G



Case study - a case of timack mfg. ltdA plywood and wooden frames Mfg. firm.Sales has reduced from £1.85m to £1.65min two year.Management took help of a ManufacturingI nstitute from E ast L ancashire Business

link.T hey identified some key issues.



T he issues were:-T he business is approximately at break even pointthere is a need to reduce cost and improve productivity, in order to start making a margin.T he manufacturing lead time is excessive,compared with the value added process time.

Stock levels are high.T

here is a seasonal trend in the business, with the busy period being March and A pril.T here is no measure of machine effectiveness.Production of samples for new products can be

problematic.



R ecommendationUse value stream mapping to identify ³waste´ within theoperation. T his will enable a plan to be produced to reducestock and lead time.

Consider a ³value stream management´ organisationalstructure.A project team was formed, consisting of the two

directors, the machine shop manager and assembly

supervisor.I mplementation of improvement took place over next four month.5S was implemented



T he photographs below show the improvedworkplace Organisation, as a result of the 5S

activityBefore After



R E SU LT S:-10% improvement in productivity (£40.9k

benefit)5% improvement in delivery performance33% reduction in stock (£54.5k benefit)33% reduction in lead time (3 weeks to 2 weeks)

2 jobs safeguarded£75k sales safeguarded10% reduction in travel distances



THANK YO U« .

Date post:	10-Apr-2018
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5s the Secret to Japnese Sucess

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