7/28/2019 5 S uses for Training
1/47
SAFETY MEETING
5 S1
7/28/2019 5 S uses for Training
2/47
2
Is a participative programme.
It is a very effective approach to improvingour work,environment and total quality.
It becomes a base for continuousimprovement in the organisation
5S---
7/28/2019 5 S uses for Training
3/47
3
Summary
5s is a systematic approach to good
housekeeping.
It is today gaining strong support in most
industries, especially in Japan and there
are increasing number of companies
which are implementing 5s with greaterinvolvement of people within the
organisation.
7/28/2019 5 S uses for Training
4/47
4
Why is it becoming popular amongcompanies in Japan? Simply because:
1. Workplace becomes clean and better organised2. Shopfloor and office operations become easier and
safer
3. Results are visible to everyone insiders and outsiders
4. Visible results enhance generation of more newideas
5. People are automatically disciplined
6. People become proud of a clean and organisedworkplace
7. Resultant good company image generates morebusiness etc.
7/28/2019 5 S uses for Training
5/47
5
Some significant benefits observedat companies practising 5s include:
1. Happier employees with high morale.2. Greater people involvement.
3. Low employee turnover.
4. Increased number of suggestions.
5. Better use of floor space.
6. Less work-in-progress and inventories.
7. Better flow of work.
8. Low machine breakdown rates.9. Low accident rates.
10. High yield of materials.
11. High product quality.
7/28/2019 5 S uses for Training
6/47
6
The assumption why 5S is becoming sopopular in Japan in recent years and in othercountries today is that it emphasizes a people-oriented and also practice-oriented approach.
5S expects everyone-indeed everyone-toparticipate in it.
It is based on the belief that every individualcan contribute to improving his/her workplacewhere he/she spends one-third of his/her life.
7/28/2019 5 S uses for Training
7/47
7
What is 5S?
The concept of good housekeeping has been with theJapanese for a very long time.At home and in school
,children are disciplined to adhere to good housekeeping
practices.However, it was only in the early 1980s that
good houskepping became a pertinent issue in Japanese
industries as companies realised its powerful contribution
to productivity and quality improvement.
The basis for good housekeeping in Japanese
companies is a concept popularly known as 5S.This
stands for the five good housekeeping concepts in
Japanese.
5 t
7/28/2019 5 S uses for Training
8/47
8
y a 5- movement1. Human beings feel good if work place is clean and well
organised.
2. Helps in reducing time
a. For searching things
b. For handling
3. Helps in reducing
a. Waste, inconsistencies & strain
b. Unnecessary items & reserve stock
c. Space requirement
d. Machine downtime
e. Rejection / Rework
f. Number of accidents
Helps people
a. In seeing things more clearly
b. In changing mindsets-develop a proactive attitude
7/28/2019 5 S uses for Training
9/47
9
Meaning of 5S
1. Segregation (SEIRI)
2. Arrangement (SEITON)
3. Cleaning (SEISO)
4. Maintenance of standards (SEIKETSU)
5. Discipline (SHITSUKE)
Wh t i 5S??
7/28/2019 5 S uses for Training
10/47
10
What is 5S??5S Original Japanese Meaning in English
1S SEIRI Sort out unnecessary items in the workplaceand discard them
2S SEITON Arrange necessary items in good order so
that they can be easily picked for use
A place for everything
Everything in its place
3S SEISO Clean your workplace thoroughly so that
there is no dust on floors,machines and
equipments
4S SEIKETSU Maintain high standards of workplace at alltimes
5S SHITSUKE Train people to follow good housekeeping
discipline automatically
7/28/2019 5 S uses for Training
11/47
11
Segregation ---SEIRIIt helps to segregate necessary and unnecessary items
and eliminate unnecessary items. It essentially meansorganising / putting things in order.
ACTIVITIES
1. Go through what you have
2. Segregate/identify what you need
3. Categorise needed/not needed items
4. Discard What Is Unnecessary
INDICATOR OF SUCCESS
1. Decrease in unnecessary items and reserve stock
2. Percentage of area / space saved
7/28/2019 5 S uses for Training
12/47
12
Arrangement --- SEITON
This step essentially means arranging items efficiently,for
easy accessibility and using them in best orderACTIVITIES
1. Set things in order by creating a place for everything.
2. Put everything in its place
3. Keep accessibility as easy as possible.
4. Use the principle of wide range and shallow depth for
storage.
INDICATOR OF SUCCESS
1. Time saved in searching
2. Time saved in handling material
7/28/2019 5 S uses for Training
13/47
How to promote good order
Putting in order
Things needed Things not needed
Things used
Constantly
Things used
occasionally
Seldom used
But still needed
Place as close
as possible
Place a little
further
Enclose in a sepearate
Designated
Place
Potentially
usefull
No potential
use
Consider where
usefull and move
to designated place
Disposal after
careful analysis
7/28/2019 5 S uses for Training
14/47
14
Cleaning ---SEISO
This step eliminates dirt, dust and other foreignmatter to make workplace clean and polished.
ACTIVITIES
1. Clean equipment, tools, furniture, records,etc.
2. Keep the workplace spotless
3. Sweeping, wiping, polishing, painting,etc.
INDICATOR OF SUCCESS
1. Reduction in machine downtime
2. Increased life of the machine parts
3. Reduction in number of accidents
4. Reduction in rejection / rework
7/28/2019 5 S uses for Training
15/47
15
Maintenance to standards ---SEIKETSU
This Step is Combination of segregation (seiri),
arrangement (seiton) and cleaning (seiso). As as,anon-going programme to maintain a clean and wellorganised workplace.
Activities
1. Create standards and initiate steps to maintain them2. Devise ways to
a. Expose hidden problems
b. Surface abnormalities
3. Create visual control systems
Indicator of success
1. Number of areas / covers made transparent
2.
Number of new problems exposed and solved
7/28/2019 5 S uses for Training
16/47
16
What is an Abnormality ?An abnormality is any gap between actual performance
and the appropriate standard
EXAMPLES
Defective goods
Scrap
Equipment Failure
Over Production Lateness
Waiting
Wh t i th i l t l ?
7/28/2019 5 S uses for Training
17/47
17
What is the visual control ?A visual control communicates required importantinformation to people who need it.
It grabs one or more of our senses in order to :
Alert us to an abnormality
Help us monitor quickly
Promote adherance and prevention Enable successful self management
Visual controls Reduce errors / waste by making problems visible Identify gap between standard and actual performance
Help in early identification of problems
Reduce supervision
7/28/2019 5 S uses for Training
18/47
18
Visual control systemA visual control system (VCS) is a series of visual
and other sensory devices integrated in order toachieve a particular outcome,ensure conformance
and prevent waste
Example
1. Illustration of correct manual operation
2. Part containers colour coded to match the parts
3. Red colour light above the line that goes on when
help is needed
7/28/2019 5 S uses for Training
19/47
19
Important Points for preparation ofvisual controls
1. Easy to see from distance
2. Easy to understand
3. Ensure correct location/ placement
4. Use colours for brightness/contrast
7/28/2019 5 S uses for Training
20/47
20
Important areas of visual displays
1. Instructions to people to avoid OPERATION ERRORS
2. Danger alerts/cautions
3. Direction/locations
4. Equipment Designations
5. Planned programmes
6. Preventive maintenance/Calibration displays
7. Appeals
7/28/2019 5 S uses for Training
21/47
21
Discipline --- SHITSUKE
This step is to ensure that everyone sticks to the
rules scrupulously and makes it a habit
ACTIVITIES
Create general awareness about 4S Training to everyone
Share success to get more enthusiasm
INDICATORS OF SUCCESS
High employee morale
Involvement of people in the movement
7/28/2019 5 S uses for Training
22/47
22
The Elements of 5S
ORGANISING/PUTTING
things in order sorting1.Removing what is not needed
2.Keeping what is needed
CLEANING
Keeping things clean andpolished,No trash or dirt
anywhere in the workplace
ARRANGEMENT
Placing things so that peoplecan easily reach what they
need whwnever they need it
MAINT.OF STANDARDS
Mainting cleanliness afterorganisation ,arrangement
and cleaning and establishing
DISCIPLINEAdherance to standards developed
through 4S steps by all employees of the
workplace
5 L l f h k i
7/28/2019 5 S uses for Training
23/47
23
5 Levels of housekeeping
LEVELS
1. Horizontal surfaces/floor full of unwanted material.
2. Vertical surfaces / areas near walls having clutter.
3. Horizontal ,vertical surfaces clean and have no unwanteditems.However,storage areas, record rooms disorganised.
4. Storage areas ,machines,offices are clean.All materials,furtinuture,documents properly organised,labelled andnumbered.
5. Factory/office is immaculate at all times.
Level 1 of Housekeeping
7/28/2019 5 S uses for Training
24/47
24
Level 1 of HousekeepingWork area is in level 1 of housekeeping if,
Cigarette butts/Gutkha pouches Scraps of paper
Tools (Used or Unused)
Packing and clamping materials
Support structures
Left -over raw material
Obsolete documents
Bulky files
Unused equipment,machine etc
are scattered around all over the workplace.
7/28/2019 5 S uses for Training
25/47
Level 2 of housekeeping
7/28/2019 5 S uses for Training
26/47
26
Level 2 of housekeepingWork area is in level 2 of housekeeping if there is no litter or
unused material on the floor/horizontal surface, but
Clutter is found by the walls
The passage ways are not clear
Unused items,documents,furniture etc are leaning against
the walls or columns
Unused tools and equipment ,paper left beneath or beside
the equipment
Corrective action for level 2
7/28/2019 5 S uses for Training
27/47
27
Corrective action for level 2
Look at vertical surfaces
Examine walls and columns
Eliminate all garbage and non- essential items leaning
against the walls/columns
Paint all walls and columns that can be reached by hand
Hint for improvement
Divide responsibilities (For area and walls)
Level 3 of housekeeping
7/28/2019 5 S uses for Training
28/47
28
Level 3 of housekeeping
Work area is in level 3 of housekeeping if the walkways are
clear and the factory/office is clean,but thetools,materials,papers and files are still disorganised in the
storage areas,record rooms,drawers,filing racks etc.
Tools ,parts,clamps are all mixed together
Gloves,shoes etc are thrown in with tools in the toolbox
Drawers,shelves are disorganised
All tools are in locked storage units
Drawers,shelves are locked and keys are missing
Unused and worthless items found inside closed cabinets
Corrective action for level 3
7/28/2019 5 S uses for Training
29/47
29
Corrective action for level 3
Look inside the shelves and sort the papers, material
,parts and tools
Get rid of locked cabinets
Make separate storages for tools,parts,clamps, documentsetc.
Make the above area distinct and clear
HINT FOR IMPROVEMENT
Remove the back and sides of all the storage cabinets
Level 4 of housekeeping
7/28/2019 5 S uses for Training
30/47
30
Level 4 of housekeeping
At level 4,the work area will have,
Machines,equipment,furnitures spotlessly clean
Storage areas clearly marked and distinguished
Scrap material found in its designated scrap bin
Items placed in shelves are properly labelled/ tagged
Storage areas show many parallel lines and right angles forgrid alignment
Tools/files are colour coded and numbered
Further improvement at Level 4
7/28/2019 5 S uses for Training
31/47
31
Further improvement at Level 4
Clean ,straighten and organise automatically
Storage system designed for First In First Outphilosophy
Develop other visual controls
Hints for improvement
Scrap and chips should fall directly into wastecontainers/dust bins
Make a model line with super market type displayof parts and tools
Well defined scrap & waste collection & disposalsystem
7/28/2019 5 S uses for Training
32/47
7/28/2019 5 S uses for Training
33/47
33
Workplace rating
In third rate workplace ,people leave trash andno one stops to pick it up
In second rate workplace, people leave trash butothers pick it up
In first rate workplace, no one leaves trash,but
people would pick it up, if they saw it.
Wh t d 5(S) i ?
7/28/2019 5 S uses for Training
34/47
34
What does 5(S) require?
Consciousness revolution through,
1. Perseverance,determination
2. Training
3. Constant efforts
Abilities
1. To see / judge what is important
2. Attention to details
Continuous implementation through
Total participation by all employees
cruc a po n s or success u
7/28/2019 5 S uses for Training
35/47
35
cruc a po n s or success uimplementation of 5S
PARTICIPATION BY ALL PEOPLE
5S programme should be participated by all People in theorganisation.
One day should be set aside for the launching of theprogramme.
6 objectives or whys of 5S programme should beunderstood by all people in the organisation,
1. A clean workplace is high in PRODUCTIVITY
2. A clean workplace has high QUALITY
3. A clean workplace keeps COST down
4. A clean workplace ensures DELIVERY on time
5. A clean workplace is SAFE for people to work
6. A clean workplace is high in MORALE
The programme would be more effective when it is
included in the small group activities like Quality Circles.
The programme requires top
7/28/2019 5 S uses for Training
36/47
36
The programme requires topmanagement commitment
The programme should be practised duringworking hours as an authorized programme,butshould not be treated as casual or extra activityduring overtime or off duty hours.
Everyone should be officially informed of thesignificance of the programme.
The CEO should personally make an officialannouncement of the launching of the programmeat an information sharing meeting attended by allpeople of the organisation.
7/28/2019 5 S uses for Training
37/47
37
The CEO should take leadership ofthe programme
The CEO himself should be keen and committed
and have a vested interest in the programme.
The CEO should not delegate the leadership to
other people.
The CEO should exercise his leadership in 5Ssteering committee.
7/28/2019 5 S uses for Training
38/47
38
The programme should besupported by all
Such doubts Why are the disposal notices posted for SEIRI
? Why is 5S improvement for shopfloor improvement?
should be eliminated.
Each committee member should keep everyone informed of
the current progress of 5S implementation on a
departmental level.
Each committee member should encourage and guide his
people for involvement in 5S implementation activities.
5S Programme should be self- sustaining
7/28/2019 5 S uses for Training
39/47
39
5S Programme should be self- sustaining
Banners,slogans,posters and newsletters should be fullyutilized to draw attention of everyone to this programme
An easy handbook or a pamphlet illustrating Why 5SWhat is 5S and How to implement 5S should be printedand distributed to everyone.
Periodic 5S implementation review should be conducted byCEO or an external expert for comments and updating thestatus quo.
Basic in-house training and introduction to modelcompanies that have successfully implemented 5Spractices would not only provide the necessary skills but
also give an insight into how other companies implement5S.
After the company has attained a certain level ofimplementation,participation in Inter- company 5Scompetition should provide greater motivation for further
improvement.
7/28/2019 5 S uses for Training
40/47
40
The CEO should make a periodic factorytour in person
The CEO should tour the factory from time to timeand point out strengths and weaknesses of 5S
implementation in each workplace.
The CEO should advise 5S steering committee to
take corrective action in the areas identified.
The CEO should check the progress of the
implementation.
The CEO should give recognition to improved orbetter practice.
7/28/2019 5 S uses for Training
41/47
41
The programme should generatesufficient impact at the initial stage
Slow implementation of decisions by the 5S
steering committee should be avoided.
Disposal notice approach for SEIRI which is the
first step to 5S should especially be implemented
company-wide for a specified time before
proceeding to SEITON which is the second step for5S.
Implementation of 5S should go hand in hand with
7/28/2019 5 S uses for Training
42/47
42
Implementation of 5S should go hand in hand withother Kaizen programme
5S especially at SEITON requires certain Kaizen principles and skills
which can be acquired via external or well organised in-house training
programmes.
SEITON requires logical problem-solving approaches.In this sense,it
can well be a good theme for Quality Circle activities.
SEITON also requires creative ideas from everyone.Therefore,it can be
tied in with and employee suggestion scheme.
Successful implementation of 5S will,by itself,bring about various
tangible results.It is also a necessary step for a company to go throughbefore implementing advanced management technologies such as
TQC,JIT and TPM because 5S buildsup a solid foundation for
SHITSUKE.
Tangible results expected from 5S
7/28/2019 5 S uses for Training
43/47
43
Tangible results expected from 5Spractice
From People
Employees will be disciplined to be more aware of untidyworkplace and motivated to improve the level ofcleanliness.
Greater team spirit and co-operation can be built upthrough involvement of all within an organisation.
Employees will be disciplined to follow safer and better
ways of work,resulting in lesser risks to accidents.
Employees would be more conscious of improvementwhich leads to greater efficiency and effectiveness.
F M hi d T l
7/28/2019 5 S uses for Training
44/47
44
From Machines and Tools
Machine troubles can be detected at an earlier
stage to prevent a major breakdown, whenmachines are cleaned daily by people operatingthem.
Daily cleaning of measuring instruments willensure accuracy and reliability.
Life of machines and tools can be extendedsignificantly when they are handled with care andplaced in the designated locations.
From materials and Work in
7/28/2019 5 S uses for Training
45/47
45
From materials and Workin -Progress
Flow of materials and work-in-progress will become
smoother.
Floor space will become organised and possible areas forimprovement can be easily identified by quick observation.
Inventory of materials and work-in-progress will become
clearly visible and easily handled.
Material yield ratios can be improved
7/28/2019 5 S uses for Training
46/47
46
From Products and Customers
Clean workplace will ensure that final products will
be free from dust.
Sales people will be eager to show customers the
plant as a marketing tool.
7/28/2019 5 S uses for Training
47/47
Housekeeping to Happiness
Housekeeping means Orderliness
Orderliness leads to Cleanliness
Cleanliness leads to Quality
Quality leads to Productivity
Productivity leads to Prosperity
Prosperity means Happiness