8/8/2019 SAP-5s
1/66
Training Session
5 Son
8/8/2019 SAP-5s
2/66
Part 1 - What is 5 S&
Part 2 - How toImplement 5 S
8/8/2019 SAP-5s
3/66
Part 1 - What is 5 S
Now, we will see !
8/8/2019 SAP-5s
4/66
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
8/8/2019 SAP-5s
5/66
INDI A
1950 1960 1970 1980
8/8/2019 SAP-5s
6/66
Seiri - Sorting
Seiton - Systematic ArrangementSeiso - Cleaning
Seiketsu - StandardizationShitsuke - Training & Discipline
What are the 5 S?
8/8/2019 SAP-5s
7/66
What isWe Will See First .!
SEIRI(SORTING)
8/8/2019 SAP-5s
8/66
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.
8/8/2019 SAP-5s
9/66
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.
8/8/2019 SAP-5s
10/66
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
8/8/2019 SAP-5s
11/66
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..
8/8/2019 SAP-5s
12/66
Seiri - Sorting Organisation
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..
8/8/2019 SAP-5s
13/66
Seiri - Sorting Organisation
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..
8/8/2019 SAP-5s
14/66
Seiri - Sorting Organisation
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..
8/8/2019 SAP-5s
15/66
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
8/8/2019 SAP-5s
16/66
Seiri - Sorting Dealing with papers
How to reduce papers on your table?
4D principleDO...
DELEGATE.DELAY.
DUMP.
8/8/2019 SAP-5s
17/66
What is Now,We Will the Second one ...!
SEITON(SYST EMATIC ARR A NG EME NT )
8/8/2019 SAP-5s
18/66
Seiton - Systematic Arrangement
SEITONA Place for Everything And...
Everything in its Place !
8/8/2019 SAP-5s
19/66
Seiton - Systematic Arrangement
How to achieve Systematic Arrangement?
Decide where things belongDecide how things should be put awayObey the Put away rules
8/8/2019 SAP-5s
20/66
Seiton - Systematic Arrangement
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.
8/8/2019 SAP-5s
21/66
Seiton - Systematic Arrangement
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
8/8/2019 SAP-5s
22/66
Seiton - Systematic Arrangement
How to achieve Systematic Arrangement?USE:
1) Signboard
2) Colour codes
3) Outline marking
4) Labels
8/8/2019 SAP-5s
23/66
Seiton - Systematic Arrangement
FunctionalStorage
8/8/2019 SAP-5s
24/66
Seiton - Systematic Arrangement
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
8/8/2019 SAP-5s
25/66
Seiton - Systematic Arrangement
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
8/8/2019 SAP-5s
26/66
Seiton - Systematic Arrangement
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
8/8/2019 SAP-5s
27/66
Seiton - Systematic Arrangement
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
8/8/2019 SAP-5s
28/66
Seiton - Systematic Arrangement
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.
8/8/2019 SAP-5s
29/66
Seiton - Systematic Arrangement
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
8/8/2019 SAP-5s
30/66
That is Now,We Will the Third ...!
SEISO( CLEA NING )
8/8/2019 SAP-5s
31/66
Seiso - Cleaning
SEISOClean workplace completely so
that, there is no dust on the floor,machines and e quipments !
8/8/2019 SAP-5s
32/66
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
8/8/2019 SAP-5s
33/66
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
8/8/2019 SAP-5s
34/66
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
8/8/2019 SAP-5s
35/66
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
8/8/2019 SAP-5s
36/66
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.
8/8/2019 SAP-5s
37/66
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.
8/8/2019 SAP-5s
38/66
Now, Fourth S is ...!
SEIK ETSU( STA ND ARDIS ATION )
8/8/2019 SAP-5s
39/66
8/8/2019 SAP-5s
40/66
Seiketsu - Sandardisation
Maintain & ImproveThe Standard of :y Seiri
y Seitony Seiso
8/8/2019 SAP-5s
41/66
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
8/8/2019 SAP-5s
42/66
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.
8/8/2019 SAP-5s
43/66
Seiketsu - Sandardisation Visual Management
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
8/8/2019 SAP-5s
44/66
Seiketsu - Sandardisation Visual Management
Some method for visual communication :
Colour codingUse of LabelsDanger AlertsIndication where things should be putDirectional arrows/ marksTransparent coversPerformance indicators
8/8/2019 SAP-5s
45/66
Seiketsu - Sandardisation Visual Management
Some method for visual communication :
Labels:
Precision management labelsInspection LabelsTemperature Labels
Responsibility labels
8/8/2019 SAP-5s
46/66
8/8/2019 SAP-5s
47/66
Seiketsu - Sandardisation Visual Management
Some everyday visual managementexample :
y Traffic signaly
Zebra crossingy In car - Petrol indicator - Speed Indicator
y Direction arrowsy Electric danger sign etc.
8/8/2019 SAP-5s
48/66
Seiketsu - Sandardisation Visual Management
Some visual communication signs :
8/8/2019 SAP-5s
49/66
And, Fifth S is ...!
SHITS UK E(TR AINING & DISCI PL INE)
8/8/2019 SAP-5s
50/66
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
8/8/2019 SAP-5s
51/66
Shitsuke - Training and Discipline
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.
8/8/2019 SAP-5s
52/66
Shitsuke - Training and Discipline
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
8/8/2019 SAP-5s
53/66
Part 2
How ToImplement 5S
8/8/2019 SAP-5s
54/66
How To Implement 5S
Step 1
Form a 5S CommitteeOR
5S Coordicator
8/8/2019 SAP-5s
55/66
How To Implement 5S
Step 2
Divide theWorkplace
into various Zones
l 5S
8/8/2019 SAP-5s
56/66
How To Implement 5S
5S format 1 Zone at work
Group Area Type of Audit Line/ Section Zone No.
H T I l 5S
8/8/2019 SAP-5s
57/66
How To Implement 5S
Step 3A llocate Zones to
the relevant people
H T I l 5S
8/8/2019 SAP-5s
58/66
How To Implement 5S
Step 4Start Implementing
y Seiriy
Seitony Seiso
H T I l 5S
8/8/2019 SAP-5s
59/66
How To Implement 5S
Step 5
Audit the 5SImplementation Process
H T I l 5S
8/8/2019 SAP-5s
60/66
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
8/8/2019 SAP-5s
61/66
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
8/8/2019 SAP-5s
62/66
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
Signature of Zone Member Sign of Auditor Date Name Dept
H T I l t 5S
8/8/2019 SAP-5s
63/66
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
Signature of Zone Member Sign of Auditor Date Name Dept
Ho To Implement 5S
8/8/2019 SAP-5s
64/66
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
8/8/2019 SAP-5s
65/66
How To Implement 5S
Step 6Give Recognitionto best 5 S Team
V P Productivity and Quality Services Nashik
8/8/2019 SAP-5s
66/66
V P Productivity and Quality Services, Nashik
Thank You
&Best of Luck !!!