Workplace Organisation
and the 5S’s
Presentation to all Team Members
WHAT IS 5S?• Developed by the Japanese• Workplace Organisation and Housekeeping System• Helps Create a Better Working Environment and a Consistently
High Quality Process• Makes the Worker’s job Easier and Safety.• Fosters efficiency and productivity while improving work flow.• Encourages a proactive approach that prevents problems and
Waste before they occur.• Fits with a facility’s other efforts, such as Total Preventive
Maintenance, Just-in-time manufacturing, Pollution prevention, Safety Initiatives and Lean Manufacturing efforts.
THE 5S PRINCIPLES
• SEIRI – Organisation
• SEITON – Orderliness
• SEISO – The Act of Cleaning
• SEIKETSU – The State of Cleanliness
• SHITSUKE - The Practice of Discipline
WHY DO IT?
QUALITY EFFICIENCY
SAFETY ELIMINATING BREAKDOWNS
5S
SORT SORT SeiriSeiri
SYSTEMATIZE SYSTEMATIZE SeitonSeiton
SWEEP SWEEP SeisoSeiso
SANITIZESANITIZESeiketsuSeiketsu
SELF-SELF-DISCIPLINE DISCIPLINE
ShitsukeShitsuke
Understanding5s
The Definition of Seiri“Sorting”
SORT SeiriSORT Seiri
Clearly distinguishing between needed and unneeded items and to dispose of these items in a systematic manner.
Definition of Seiton“SINUPIN”
• Seiton is the arrangement of necessary items into good order so that they can easily selected for use. • It is arranging needed items so that they are easy to use and labeling them to make their storage sites understandable at a glance.
SORT SORT SeiriSeiri
SYSTEMATIZE SYSTEMATIZE SeitonSeiton
The Definition of Seiso“SIMUTIN
• Seiso is cleaning up one’s workplace completely so that there is no dust on floors, machines or equipment.• Keeping everything swept and clean and includes finding ways to prevent the accumulation of dirt and dust in farm equipment and facilities.
SORT SORT SeiriSeiri
SYSTEMATIZE SYSTEMATIZE SeitonSeiton
SWEEP SWEEP SeisoSeiso
Definition of Seiketsu“SIGURUHIN ANG
KALINISAN”
•Seiketsu is maintaining one’s workplace so that it is productive and comfortable by repeating Seiri-Seiton-Seiso.
• To cultivate Clean, fresh, spotless workplace where everyone adheres to prescribed procedures.
SORT SORT SeiriSeiri
SYSTEMATIZE SYSTEMATIZE SeitonSeiton
SWEEP SWEEP SeisoSeiso
SANITIZESANITIZESeiketsuSeiketsu
•Shitsuke is training people to follow good work habits and the strict observation of workplace rules. •It means to cultivate a disciplined work/farm place where everyone is doing something on their own to maintain a clean environment and to correctly understand the 5S philosophy
The Definition of Shitsuke
“Sariling-Kusa”
SORT SORT SeiriSeiri
SYSTEMATIZE SYSTEMATIZE SeitonSeiton
SWEEP SWEEP SeisoSeiso
SANITIZESANITIZESeiketsuSeiketsu
SELF-SELF-DISCIPLINE DISCIPLINE
ShitsukeShitsuke
he
teeringommittee
S
A 5s Steering Committee is the farm’s governing body on all 5S Related activities.
It is primarily responsible for the over-all planning, implementation, and review of all activities.
It is tasked to formulate the farm’s Master Implementation/Action Plan, conduct 5s evaluation or audits, promote 5s at all levels of organizations, strategize promotional activities and monitor the progress and sustenance of the 5s program.
Sctionlan
The 5s Action plan describes the activities to be undertaken, by step, phase and month.
It serves as a guide and reminder to your farm workers and the committee members of their responsibilities and schedule of delivering required outputs, of the necessary activities to be undertaken to attain the program objectives, and of their monthly progress.
VISUAL CONTROL
5SActivities at the
Farm
Visual control means the use of a variety of graphic displays or labels which are just as important in the farm setting.
These visual devices are used:
to tell how things should be and how they actually are so that if there are abnormalities, they can be corrected before damage is done;
To detect abnormalities and prevent its occurrence
To ensure efficient production of quality produce
To prevent or minimize accidents.
EFFICIENCY
• Time is wasted looking for tools, equipment and paperwork, etc
• A clean and tidy workplace leads to greater well being and increased motivation
• Teamworking makes unexciting work more rewarding
ELIMINATE BREAKDOWNS
• Breakdowns caused by the elimination of dirt need never occur
• Clear labelling and routine maintenance are essential disciplines
• A clean workplace highlights problems early
SAFETY• Dirty cluttered workplaces are not safe
• Safety depends on good care and organisation
• Safety should become second nature
ORGANISATION• Decide what you need
• Remove unnecessary clutter
• All tools, gauges, materials, classified and stored
• Remove items which are broken, unusable or only occasionally used
ORGANISATION
PRIORITY FREQUENCY OF USE HOW TO USE
Low Less than once per yearOnce per year
Throw awayStore away from the workplace
Average At least 2/6 monthsOnce per monthOnce per week
Store together but offline
High Once Per Day Locate at the workplace
ORDERLINESS• Organise layout of tools and equipment
– Designated locations– Use tapes, labels and silhouettes
• Ensure everything is available as it is needed and at the “point of use”
ORDERLINESSWorkplace Checkpoints:-• Positions of aisles and storage places clearly
marked?• Tools classified and stored by frequency of use?• Pallets stacked correctly?• Safety equipment easily accessible?• Floors in good condition?• Lights / Reflectors clean?
CLEANING
• Create a spotless workplace
• Identify and eliminate causes of dirt and grime – remove the need to clean
• Sweep, dust, polish and paint
CLEANING• Divide areas into zones
• Define responsibilities for cleaning
• Tools and equipment must be owned by an individual
• Focus on removing the need to clean
STANDARDISING• Keep it clean and/or organised• Replace items in designated areas• Continue to assess the use and disposal of
items• Regularly audit using checklists and measures
of housekeeping• Real challenge is to keep it clean
DISCIPLINE• Make it a way of life• Part of health and safety• Involve the whole workforce• Follow the rules and procedures• Develop and keep good habits• Think and share ideas with others• Encourage teams to set their own standards
EXTRACT FROM A REAL PLAN SHOWING HOW
AUDITING AGAINST 5S BECOMES A WAY OF LIFE
Area Responsible Person
Auditors: Audit to be carried out by 3rd week of each month by named person and an assistant…July Sept Nov
Boiler House, Site, Car park
Brian Sutherland
Ronnie Wilson
Linda Johnstone
Neal Robertson
Stockroom Kevin McEwen Linda Johnstone
Neal Robertson
Brian Sutherland
Sales Sandra Collins Neal Robertson
Brian Sutherland
Helen Graham
BENEFITSImprovements in:-• Workforce morale• Company image• Health and Safety• Machine maintenance• Quality • Productivity
Leading to Increased Competitiveness
This diagram was developed using an idea that Nissan of Sunderland taught the JIT Club and links
housekeeping to Health & Safety.
Health & Safety Audit Spider Graph Summary
012345
Electrical
Chemical
Fire
Machinery
Storage & Handling
HousekeepingOct-99
If you have any queries about this material, please contact the author:
Greig Sneddon,
Operations Manager,
Seaborne Plastics Ltd,
Unit 3-4, Manfield Park Ind. Est.,
Cranleigh,
Surrey
GU6 8PT
competitivescotland.com
5SActivities at the
Farm
Visual Control can be applied to a variety of tasks or situation within the farm:
Monitoring – ex. For medications, feeding and nutrition like the tags or notches used.
Classifying – chart to give the location of each file
Improving Efficiency –reducing the time to look for an item
Differentiating and Coordinating – for storage, operations, equipment, quality and safety.
Setting the 5s Standards and Guidelines at your
farm
Conducting the 5s Audit
Sustaining 5S
This simply means that these activities must be done continuously or at regular intervals.
It can be viewed as “a cycle of continuous improvement where activities are constantly upgraded in terms of style, quality, delivery and performance.