5s

understand 5s in 5 mins !

In JAPAN..1943

Hello!Iam Taichi Ohno ... Father of TPS

“I worked in a small company as a floor supervisor which used to make spinning mill machinery. With a single minded goal of achieving the highest standard quality and efficiency we made this company into the biggest car manufacturer in the world. We are TOYOTA

Today the world follows

us...let's learn about one of the CONCEPTS we developed at Toyota THE 5’s

5s -Seiri, Seiton,Seisio,Seiketsu and

ShitsukeDon’t waste time byhearting these words..

why 5s?

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The more clutter = more time wasted finding stuff

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Visual Clarity = Safety

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Clean and aesthetically neat= less stress for workers

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Standardization = easy to train new workers

“ULTIMATE GOAL : IMPROVE QUALITY, REDUCE COST and SHORTEN LEAD TIME

HOW ?

let's go through the 5 Steps which will help you implement 5s.

What you need

1.Right Attitude 2.TEAM work3.5s Stationary : floor marking tapes different colors, Paints , scale, alignment rope, paint brushes,4. 5s main control board 4. Cleaning material

Step 1 : SORT

This deals with dividing things lying around into two : Necessary items and Un necessary items

1.1.SORT STEPS-

Removing unnecessary things1. Identify area for 5s, Take lot of BEFORE photos, make a team.

2. Define criteria for unnecessary

3. Mark all the items which meet criteria with a red tag /red paint, goal of at least 10 tags by each ten member

4. Create a red tag area remove and place all the red tag material in that area to be disposed off / scrapped/ moved to a different location

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Step 2 : Set in order

Organising the necessary things in the best possible manner

1.1.Set in order stage-

Organising what’s left1. Place necessary items according to the frequency of their use

2.Criteria is there should be least movement of worker to get the right equipment

3. Label and categorise necessary things , put lot of boards for easy identification

4. USE tapes and paints to mark the final position of each item/equipment.

5. Take photographs

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Step 3 : SHINE

This deals with General cleanliness, dust removal, disinfect and repaint the area ..

1.1. SHINE STEPS-

Sweep, Sanitize Scrub1. Make the floor, equipment and machinery shine

2. Repaint if required.

3. After authorization clear the red tag material from the premises

4. Cleaning inspection and correction

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1.1.

Step 4 : Standardize

This deals with standardizing the process and practices with respect to step 1 , 2 and 3

1.1.Standardize STEPS-

standardize the process and practices1.Make Standard Process flow for each location

2. Document Standard process and training material

3.Self checklists to be made for each team member and role 4.Develop procedures, Schedules and Practices

5.All employees must be able to understand and change stations easily:somebody who is a dispatcher in one unit should be able to do dispatching in any unit of the company easily

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Step 5 : Sustain

Aim of this step is every team member should follow and sustain 5s without being told “5s is not a one time activity, its a style of doing work deeply inculcated in each and every team member”

1.1.SUSTAIN -

MOST DIFFICULT PART OF 5s1. Inspect before and after working

3.Keep encouraging and recognising those who participate and never ignore those when slacken

4.Use Information Boards to provide recognition to the team and to show visitors what has been achieved

5.Keep talking about the 5S, don’t let them become a low status activity

6.Use the results of 5S audits to drive continuous improvement

7. Always be ready to “Red Tag”, or run further Red Tag events

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5s in action

5s in various work settings

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“

“ Ask ‘why’ 5 times on every matter to understand them clearly- Taichii Ohno”

Any questions?You can find me at Abhishek@tplay.inFacebook www.facebook.com/tplay.in

Visit us www.tplay.in

Thanks!