Qimpro Champion League:
Challenge 1: 5S
(COLLEGE LAB)
INDIAN INSTITUTE OF FOREIGN TRADE (IIFT)
Pranjal Parihar
Vivek Maheshwary
Anukriti Singh
WHAT IS 5S??? Name of the workplace organisation method
Identified as one of the techniques that enabled just in time manufacturing
5S stands for five Japanese words all starting with English letter ‘S’
Seiri (Sort)
Seiton (Set in Order)
Seiso (Shine)
Seiketsu (Standardize)
Shitsuke (Sustain)
ADVANTAGES OF 5S Reduce workflow problems.
increases product quality and productivity
Improve workplace safety
Align employee efforts with goals and strategies for eliminating waste.
1S. SORT
Separate necessary
items and the
unnecessary items
and dispose
unnecessary items
properly
2S. SET IN ORDER
Arranging all the
items in a particular
order for easy use and
reduce searching time
for a particular tool
3S. SHINE
Cleaning the
workplace and
maintaining its
appearance daily by
establishing
preventative
measures to produce
on going cleanliness
4S. STANDARDIZE
Maintain and make
the ‘sort’ ,’ set in
order’ and ‘shine’
habitual. 5S
becomes a part of
regular work routine.
5S. SUSTAIN
Ongoing application
of knowledge , skills
and abilities gained
from 5S process.
Improving
organisational
effectiveness.
5S
POOR 5S PRACTICES 1. SORT
Necessary items are mixed with
unnecessary items
Unnecessary items are lying in
the work area
2. SET IN ORDER
No differentiation between
necessary tools, equipment, etc.
Location of unnecessary items
are not clearly defined
No Designated & permanent
locations for items
3. SHINE
The area is not cleaned thoroughly
Cleaning & inspection of areas are not
taking place daily
4. SUSTAIN
No proper SOPs are there;
There is no proper documentation of
equipment & processes
No audit schedule is there
POOR 5S PRACTICES contd.
QUANTIFICTION OF THE PROBLEM
21%
16%
28%
35%
SET IN ORDER Not keeping the setup for experiments inorder
Not arrangingingstudents in group in asystematic order
Irregular sequence ofexperimentsperformed (theorylags behind praticalsessions)
Not keeping theequipemnts in properplace
47 hours Increase in time for
conducting lab experiments (monthly)
because of not following SORT. Above
reasons causing the % of time
occupied in SORT.
30 hours Increase in time for
conducting lab experiments
(monthly) by not following SET.
Above reasons causing the % of time
occupied in SET.
33%
51%
16%
SORT Searching time forinstruments
SepratingNecessary itemsfrom unnecessaryitems
RemovingUnncessary itemsfrom work area
43%
26%
31%
SHINE
Not wearing labcoats, gogglesand gloves
No daily cleaningof the floor
No regularcleaning of theworking area
16 hours Increase in time for
conducting lab experiments
(monthly) because of not following
SHINE. Above reasons causing the %
of time occupied in SHINE.
QUANTIFICTION OF THE PROBLEM
12 hours Increase in time for
conducting lab experiments
(monthly) because of not following
STANDARDIZE. Above reasons
causing the % of time occupied in
STANDARDIZE.
20%
27% 33%
20%
STANDARDIZE Not stickingquipment name onrespectiveequipments
No proper SOPs
No full time labassistants
No proper recordkeeping of theequipments
SUSTAIN:
Because of above problems, approximately 105 hours are wasted
for conducting lab experiments (monthly). It does not add any
value.
Using of 5S technique and continuously improving above, reduces
this wastage time
Effective utilization of human resources can be increase by using
this technique
QUANTIFICTION OF THE PROBLEM
RECOMMENDATIONS
1. SORT
Establish a holding area for items (Red Tag area)
Identify items not required at the current location, if at all
Team members evaluate items in Red Tag area
2. SET IN ORDER
Define the major processes (experiment) performed
For each process, draw a map of the locations of each activity
Identify sources of waste and corrective measures
Position items where they are needed based on frequency
3. SHINE
Fix leaks & other problems
Inspect daily
Fix potential issues before they become major problems
4. STANDARDIZE
Develop SOPs
Document equipment & processes
Develop audit schedule and assign tasks to individuals
Establish a methodology to ensure consistent strategy for 5S
implementation
RECOMMENDATIONS
5. SUSTAIN
Daily Checklist which looks at the cleaning of equipment and floor,
no unnecessary items, location and position of tools and storage,
condition of storage area
Weekly/Fortnightly Audit of lab by Non-lab personnel formally check
for things out of place, using same checklist
Lab In-charge: Taking Informal Walks through Lab to look for
potential problems,
A Visual Board: To Show information about & results of 5S
RECOMMENDATIONS
How to quantify the general problem in the terms of time and cost
Advantages of 5S in industry perceptive
How to identify and separate the problems.
Good 5S Practices proves to be the best if they are brought in
application.
Implementation of 5S technique in daily life .Better organize
ourselves by like pasting stickers on books to differentiate them
clearly in the rack, keeping our surroundings, room and study table
clean etc.
Utilization of resources in a effective manner
How to use bar and pie chart for quantifying the problem
Help the students to face the competitive world in future.
Working in a team and sharing and exchanging ideas with team
members.
LESSONS LEARNED BY THE TEAM