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Training Session

5 Son

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Part 1 - What is 5 S&

Part 2 - How toImplement 5 S

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Part 1 - What is 5 S

Now, we will see !

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QUAL ITYQUAL ITY

SAFE TYSAFE TY

EFF ICIE NCYEFF ICIE NCY

CONTRO LCONTRO L

Customer Satisfaction

EmployeeSatisfaction

Eq uipment

MaterialJigs/Tools

Method

Workers

Products

Timeliness

Motivates

Impact of 5 S at the Workplace

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INDI A

1950 1960 1970 1980

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Seiri - Sorting

Seiton - Systematic ArrangementSeiso - Cleaning

Seiketsu - StandardizationShitsuke - Training & Discipline

What are the 5 S?

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What isWe Will See First .!

SEIRI(SORTING)

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Seiri - Sorting

SEIRI - SORTING /REORGANISATIONTo clearly devide objects in to two groups

Those items that are necessary.And Those items that are not necessary.

To get rid of the unnecessary and to keep thenecessary.

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Seiri - Sorting

WHAT IS UNNECESSARYItem is not needed.

Item is needed however, quantity in stock is morethan what is needed for consumption in near future

Contingency Parts : Critically decide the quantity

of contingency parts to be retained and criteria for such parts.

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Seiri - Sorting OrganisationFrequency of use Storage Method

Things you have not used Throw them outin the last one year.Things you have used once Store at distance OR in the last 6-12 months. Keep in store

Things you have used only Store it in centralonce in the last 2-6 months. place in your zone.Things used more than once Store it in the centrala month. place in your zone

Things used once a week Store near theworkplace.

Things used daily or hourly Store near theworkplace.

LOW

HIGH

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Seiri - Sorting Organisation

Identifying unnecessary1) Parts and Work in Process (WIP)Things fallen back behind the machine or rolledunder it.B roken item inside the machine

Things under the rack/platforms.Ex tra WI PStock of rejected itemsItems accumulated over period for rework Material awaiting disposal decisionMaterial brought for some trail, still lying even after trailSmall qty of material no longer in use Cont..

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Identifying unnecessary2) Tools, Toolings, Measuring devicesOld jigs, tools not in use lying.Modified tools, tooling for trial, are lying after trail.Worn out items like bushes, liners, toggles etc. lying.

B roken tolls, bits etc. may be lying.Measuring e quipment not re quired for the operation being performed, is lying.

3) Contingency partsMany times storage place for contingency parts become a lastrefuge for broken parts, surplus items and things nobody islikely to use. Cont..

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Identifying unnecessary4) Shelves and Lockersy Shelves and lockers tends to collect things that nobody ever uses, like surplus, broken items etc.

5 ) Passage and Corners :y Dust material not re quired seem to gather in corner.

6 ) Besides Pillars and under the stairs:y These place tends to collect junk, spittoon etc.

7 ) Walls and Bulletin Boardsy Old out dated notices which have lost their relevancey Posters or bulletins on wally Dust, remain on torn notices, cell tape pieces Cont..

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Identifying unnecessary8) Floor, Pits, Partitionsy Defective partsy Protection caps, coversy Packing materialy

Hardware items, small itemsy Even tools,small itemsy Even tools, tooloingy Items dropped on the floor are never picked

9 ) Computer Hard Disk Many unwanted, outdated, temporary files pile up

Cont..

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Seiri - Sorting Dealing with papers

How to reduce papers on your table?

1) Make a single pile of papers

2) Go through them and sort in following categories :

a) Immediate action b) Low priorityc) Pendingd) Reading materiale)For information

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Seiri - Sorting Dealing with papers

How to reduce papers on your table?

4D principleDO...

DELEGATE.DELAY.

DUMP.

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What is Now,We Will the Second one ...!

SEITON(SYST EMATIC ARR A NG EME NT )

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Seiton - Systematic Arrangement

SEITONA Place for Everything And...

Everything in its Place !

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How to achieve Systematic Arrangement?

Decide where things belongDecide how things should be put awayObey the Put away rules

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How to achieve Systematic Arrangement?Decide where things belong- Standardize Nomenclature- Determine an analytical method for storage

Decide how things should be put away- Name & location to everything. Label both item

and location- Store material functionally- Prevent mistake with coding by shapes & colour

contd.

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How to achieve Systematic Arrangement?Decide how things should be put away- Follow first in first out rule- If two identical items are to be located, then store

them separately, colour code them.

Obey the rules

- Put the things back to their location after their use

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How to achieve Systematic Arrangement?USE:

1) Signboard

2) Colour codes

3) Outline marking

4) Labels

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FunctionalStorage

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Functional StorageUsage * Store fre quently used materialFrequency near the workplace and

less fre quently at some distanceWeight & * Heavy material should be storedShape of at lower levels/layers

the Material Place directly on the materialhandling device for case of handling

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Functional StorageCategory * Same category of material may

be stored in one location.Eg. Allen Screws, Oil Seals

Operation * All items re quired for anWise operation may be stored in one

location.Eg. Allen key, spanner etc. hand

tools re quired for setting m/c

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Functional StorageOutlining and Placement Marks

-Marks boundaries of dept. aisles, Machines-Follows straight line, right angle rule-Nothing shall be kept outside the boundaries

Stand and shelves-Keep only re quired number of stands andshelves

-Standardize height, size-Provide casters where necessary so that it can

be move

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Functional StorageWires and Ducts- Colour code- When there are multiple connections bundle the wires,

label them and lake 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 tools should be such that it can be putaway with one hand

- Try to eliminate some hand tools by permanentlyattaching it to the bolthead

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Functional StorageBlades, Dies other important consumables

- Stores 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 theyare not mislabeled.

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Functional StorageOils

- Reduce number of oils used (Standardize)- Colour code for oil

- Safety aspects fire prevention, pollution,leak, spillage

Instrumentation & Measuring Devices- Label them, show direction of flow

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That is Now,We Will the Third ...!

SEISO( CLEA NING )

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Seiso - Cleaning

SEISOClean workplace completely so

that, there is no dust on the floor,machines and e quipments !

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Seiso - Cleaning

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

inspection

Success - Reduction in machine down time

Indicator - Reduction in no. of accidents

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Seiso - Cleaning

While cleaning up and getting rid of dirt and unclear items potential defectssuch as A brasion, Damage, Loose

Parts, Deformities, Leaks, Vibration,A bnormal Sound etc., are revealed andhence Seiso is inspection

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Seiso - Cleaning

Here cleaning means more than justkeeping things clean. Cleaning should be viewed as a form of Visual

InspectionPreventive measures should be taken to

tackle problems of dust, grim, burrs,leakage etc. Roots cause of the problemshould be identified and it should be

eliminate

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Seiso - Cleaning

5 Minutes Every day for cleaning

Devote 5 minutes every day for cleaning your work areaParticipation of everyone is re quired

Attack hard to clean places regularly

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Seiso - Cleaning

Cleaning - Inspection Points for mostequipmentTightening Loose bolts, welding detachment,

loose parts, vibration or bumping noise,friction

Heat Oil tanks, motors, heaters,axles, control panels, washing/cleaningwater, bearing, wiring etc.

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Seiso - Cleaning

Cleaning - Inspection Points for mostequipment

Breakage, B reakage, cracks dent on slidingCracks parts, handle has come off,

broken switches, wire jointscome off, wires are broken or crack dial of various pre, gauge,meters etc.

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Now, Fourth S is ...!

SEIK ETSU( STA ND ARDIS ATION )

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Seiketsu - Sandardisation

Maintain & ImproveThe Standard of :y Seiri

y Seitony Seiso

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Seiketsu - Sandardisation

Regularizing 5S activities so thatabnormalities are revealed.Make it easy for everyone to identifythe state of normal or abnormalcondition

For maintaining previous 3 S, deployvisual management

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Seiketsu - Sandardisation Visual Management

It has been estimated by scientific studythat 60% of all human activities startswith sight

5S is easy to do once. It is consistencythat is difficult. That is why VisualManagement is so important, so thatevreybody will know that there is some

problem.

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What visual controls communicates?

It grabs one or more of our senses in order to

y Alert us to an abnormalityy Help us recover quicklyy Promote adherence and preventiony Enable successful self management

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Some method for visual communication :

Colour codingUse of LabelsDanger AlertsIndication where things should be putDirectional arrows/ marksTransparent coversPerformance indicators

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Some method for visual communication :

Labels:

Precision management labelsInspection LabelsTemperature Labels

Responsibility labels

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Some everyday visual managementexample :

y Traffic signaly

Zebra crossingy In car - Petrol indicator - Speed Indicator

y Direction arrowsy Electric danger sign etc.

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Some visual communication signs :

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And, Fifth S is ...!

SHITS UK E(TR AINING & DISCI PL INE)

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Shitsuke - Training and Discipline

We need everyone to maintain 5Sguidelines.

To maintain DISCI PL INE, we need to

practice and repeat until it becomes a wayof life.

Discipline is the Core of 5S

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Discipline means making a steadyhabit of properly maintaining correct

procedures.

Time and effort involved inestablishing proper arrangement and

orderliness will be in vain if we do nothave discipline to maintain it.

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PledgeIt shall be my constant effort to maintainmy workplace in good order by

y Assign a place for everything &keeping everything in its place

y Sorting out unwanted material

periodically and discarding themy Keeping my work area neat & clean

everyday

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Part 2

How ToImplement 5S

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How To Implement 5S

Step 1

Form a 5S CommitteeOR

5S Coordicator

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How To Implement 5S

Step 2

Divide theWorkplace

into various Zones

l 5S

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How To Implement 5S

5S format 1 Zone at work

Group Area Type of Audit Line/ Section Zone No.

H T I l 5S

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How To Implement 5S

Step 3A llocate Zones to

the relevant people

H T I l 5S

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How To Implement 5S

Step 4Start Implementing

y Seiriy

Seitony Seiso

H T I l 5S

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How To Implement 5S

Step 5

Audit the 5SImplementation Process

H T I l 5S

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How To Implement 5S

5S format 25S Audit Calendar For the month of :

S. No. Name Area of Audit Type of Audit Zone Dates

H T I l t 5S

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How To Implement 5S5S format 3 5S AU DIT CH ECK LIST S UPP ORT GRO UP

5S Points Mark Range Marks1. SEIRI (SORTING)a) IT EMS/ PROC ESS M ATL/INSTR UME NTS SORT ED & ID E NTI FIED AS 1-10

OK, Usable immediatelyUsable (Spares)Good, Not Re quiredRework Scrap

b) FILES A ND R ECORDS SORT ED A ND ID E NTI FIED AS 1-5Current/ Follow up

Not Re quired (to be sent to Record Room)c) A NY IT EM / FILE S/R ECORDS LYING U NSORT ED 1-5

SUB -TOT AL2. SEITON (SYST EMATIC ARR A NG EME NT)a) Table, Chairs, Cupboards, Racks & B ins Neatly Arranged 1-5

b) Items neatly arranged and identified as Under process/Spares/Scrap 1-5c) Arrangement of files in Filing Rack 1-5d) Any items /files lying haphazard 0 or 5

SUB -TOT AL3. SEISO (Cleanliness)

a) Tables, Chairs, Machines 1-5 b) Surroundings Area free of oil, chips, cotton waste etc. 1-5c) Floor, wall, (Including Glass of Windows & Ventilation) Ceiling (Tube Light, Fans & Roof) 1-5d) Measures taken to consume electricity 1-5

SUB TOTALTOTAL

Signature of Zone Member Sign of Auditor Date Name Dept

H T I l t 5S

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How To Implement 5S5S format 4 5S AU DIT CH ECK LIST PROD UCTION GRO UP

5S Points Mark Range Marks1. SEIRI (SORTING)a) IT EMS/ PROC ESS M ATL/INSTR UME NTS SORT ED & ID E NTI FIED AS 1-10

OK, Usable immediatelyUsable (Spares)Good, Not Re quiredRework Scrap

b) FILES A ND R ECORDS SORT ED A ND ID E NTI FIED AS 1-5Current/ Follow up

Not Re quired (to be sent to Record Room)c) A NY IT EM / FILE S/R ECORDS LYING U NSORT ED 1-5

SUB -TOT AL2. SEITON (SYST EMATIC ARR A NG EME NT)a) Table, Chairs, Cupboards, Racks & B ins Neatly Arranged 1-5

b) Items neatly arranged and identified as Under process/Spares/Scrap 1-5c) Arrangement of files in Filing Rack 1-5d) Any items /files lying haphazard 0 or 5

SUB -TOT AL3. SEISO (Cleanliness)

a) Tables, Chairs, Machines 1-5 b) Surroundings Area free of oil, chips, cotton waste etc. 1-5c) Floor, wall, (Including Glass of Windows & Ventilation) Ceiling (Tube Light, Fans & Roof) 1-5d) Measures taken to consume electricity 1-5

SUB TOTALTOTAL


H T I l t 5S

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How To Implement 5S5S format 5 5S AU DIT CH ECK LIST ADMINISTR ATIV E GRO UP

5S Points Mark Range Marks1. SEIRI (SORTING)a) Records, files with clear Labeling 1-10

b) Memos / Letters Sorted out for Filling/ Action/ Follow-up 1-5c) Any Items/ Files/Records lying unsorted 0 or 5

SUB -TOT AL

2. SEITON (Systematic Arrangement)a) Work Table, Chairs and Personal B elongings 1-5

b) Layout of office & office e quipment (filling cabinet, Waste Paper B ins, Computers & Stationary 1-10c) Any items/ Files Lying Haphazard 0 or 5

SUB TOT AL

3. SEISO (Cleanliness)a) Tables, Chairs, Computers 1-5

b) Cupboard, Filing Cabinet 1-5c) Floor, wall, (Including Glass panes of Windows & Ventilators) Ceiling (Tube Light, Fans & Roof) 1-5d) Measures taken to consume electricity 1-5

SUB TOT ALTOT AL


Ho To Implement 5S

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How To Implement 5S

5 S NOTIC E B OARD

1 AR EA P RO B LE MS FOR GRO UP 5S ASSESM E NT CH ARTDATE

2 ZON E

3 LEA DER TOD AY TOD AY LA ST MONYHAVER AGE AVER AGE

SEIRI

4 PA RTICI PA NT S EITON

SEISO

TOTAL

How To Implement 5S

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How To Implement 5S

Step 6Give Recognitionto best 5 S Team

V P Productivity and Quality Services Nashik

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V P Productivity and Quality Services, Nashik

Thank You

&Best of Luck !!!

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