5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems). These are foundational to Kaizen (continuous improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts. 5S is one of the activities that will help ensure any company’s survival.
5S 1. Sort - All unneeded tools, parts and supplies are removed from the area 2. Set in Order - A place for everything and everything is in its place 3. Shine - The area is cleaned as the work is performed 4. Standardize - Cleaning and identification methods are consistently applied 5. Sustain - 5S is a habit and is continually improved Also - Work areas are safe and free of hazardous or dangerous conditions
Some New Words Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes Some Japanese words one need to know: Kaizen-(pronounced “kai zen”) – Continual improvement Muda-(pronounced “moo da”) - waste Gemba-(pronounced “gim ba”) – workplace Kanban-(pronounced “kon bon”) - Pull type inventory control system. Items are only produced to meet customer needs. The request to produce more is signaled from an upstream operation and/or customer orders.
KAIZEN: What it is? 1)Process Improvement 2)Observation 3)Use of New Paradigms 4)Short Time 5)Zero Investment 6)Human Development & Empowerment 7)Profits & Savings - Plenty
ALWAYS CONTINUAL CHANGE GOOD IMPROVEMENT FOR THE BETTER
KAIZEN IS A JOURNEY FROM: EVENT RESULT GROSS ENFORMENT OF CHANGE TO CAUSE TO PROCESS TO MICRO TO INDUCEMENT OF CHANGE
KAIZEN IS CONTINUAL IMPROVEMENT TIME IMPROVEMENT
KAIZEN: KNOW THE REALITY THROUGH YOUR SENSE OBSERVATIONINTELLIGENCE PHYSICAL EFFORT PARADIGM OF HIGH PRODUCTIVITY & QUALITY
KAIZEN AT GEMBA GEMBA: PLACE OF WORK GEMBA is where... Value is added Actual work is done to meet customer requirement Problems are solved Staff is responsible for providing support, not for giving instruction
12 1. 5S Principles Elimination of waste Elimination of waste Every body is involved, Every body is involved, Co-operative effort Co-operative effort Attack root cause Attack root cause Human being is not infallible Human being is not infallible
13 2. Objectives Improve housekeeping Make every individual responsible for housekeeping Beautify by simple means Productivity improvement by saving time, space etc.
The ‘S’Japanese WordWhat is involvedObjective 1S SEIRI (Sorting Out) Segregate necessary from unnecessary Remove what is not required Decide on frequency of sorting Saving and recovering Space 2S SEITON (Systematic Arrangement) Arranging in order Place for everything, Everything in its place Minimizing search time 3S SEISO (spic and Span) Cleaning the work place/ equipment Attaining the warning bell Inspecting for problems Taking corrective actions faster 4S SEIKETSU (Standardizatio n) Working Methodology (Procedures & WI) Achieving higher productivity and better quality 5S SHITSUKE (Self Discipline) Forming the habit in form of Training and Discipline Doing it right at First Time
16 SEIRI = Sorting Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items Activity Establish a criteria for eliminating unwanted items Eliminate unwanted items either by disposing them or by relocating them. Success Area saved or percentage of space available Indicator
17 SEIRI = Sorting Japanese Meaning : The Japanese meaning of “Seiri” is to straighten and contain. - Get rid of waste and put it in order according to rules Japanese Meaning : The Japanese meaning of “Seiri” is to straighten and contain. - Get rid of waste and put it in order according to rules
1 ‘S’ – Our respiratory system sorts oxygen and other gases. And exhales other gases which are unwanted for our body 1 ‘S’ - SEIRI
Sort for... N ot Needed at All N eeded but not Now N eeded but not here N eeded but not so much Quantity 1 ‘ S’ WANTEDUNWANTED 1S – SEIRI : SORTING
20 1. Item is not needed 2. Item is needed however quantity in stock is more than what is needed for consumption in near future 3. Contingency Parts Critically decide the quantity of contingency parts to be retained and criteria for such parts Seiri = Sorting What is unnecessary
21 Frequency of useStorage Method *Things you have not used in the past one year Throw them out *Things you have used once in the last 6-12 months Store at distance OR Keep in store LOW *Things you have used only once in the last 2-6 months Store it in central place in your zone *Things used more than once a month Store it in central place in your zone AVERAGE HIGH *Things used once a week Store near the workplace *Things used daily or hourly Store near the workplace Organization
22 Seiri = Sorting Identifying unnecessary 1. Parts & Work in Process (WIP) Things fallen back behind the machine or rolled under it Broken items inside the machine Things under the racks/ platform Extra WIP Stock of rejected items Items accumulated over period for rework Material awaiting disposal decision Material brought for some trial, still lying even after trial Small qty of material no longer in use Contd..
23 Seiri = Sorting Identifying unnecessary 2. Tools, Tooling, Measuring devices Old jigs, tools not in use are lying Modified tools, tooling for trial, are lying after trial Worn out items like bushes, liners, toggles etc. lying Broken tools, bits, etc. may be lying Measuring equipment not required for the operation being performed, is lying 3. Contingency Parts Many times storage place for contingency parts become a last refuge for broken parts, surplus items and things nobody is likely to use Contd..
24 Seiri = Sorting Identifying unnecessary 4. Shelves and Lockers Shelves and lockers tends to collect things that nobody ever uses, like surplus, broken items etc. 5. Passages and Corners Dust, material not required seem to gather in corner 6. Besides Pillars and under the stairs These places tends to collect junk, spittoon etc. 7. Walls and Bulletin Boards Old out dated notices which have lost their relevance Posters or bulletins on wall Dust, remains of torn notices, cell tape pieces Contd..
25 Seiri = Sorting Identifying unnecessary 8.Floor, Pits, Partitions Defective parts Protection caps, covers Packing material Hardware items, small items Even tools, tooling Items dropped on the floor are never picked 9.Computer Hard Disk Many unwanted, outdated, temporary files pile up
26 Seiri = Sorting Improvement methods 1. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system e.g. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for system e.g. How to perform Seiri (sorting) 3. Check List A check sheet is used to decide what sort of main system and sub system are necessary.
27 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 priority c) Pending d) Reading material e) For information
28 Seiri = Sorting Dealing with papers How to Reduce Papers on Your Table ? 4 D Principle 4 D Principle DO DELEGATE DELAY DUMP
2 ‘S’ Seiton : Systematic Arrangement Arranging things in systematic way
2 ‘S’ – In our body there is a fixed place for every organ. 2 ‘ S’ - SEITON
31 SEITION = Systematic Arrangement Meaning To determine type of storage and layout that will ensure easy accessibility for everyone. Activity - Functional storage - Creating place for everything and putting everything in its place Success- Time saved in searching Indicator - Time saved in material handling
32 SEITION = Systematic Arrangement Japanese Meaning: Dictionary meaning of Seiton is “to be correctly prepared” and “to prepare correctly”. In short these means : (a) arrange correctly in accordance with the correct method of doing activities and (b) make thorough preparations so that activities can be done even if they occur abruptly Japanese Meaning: Dictionary meaning of Seiton is “to be correctly prepared” and “to prepare correctly”. In short these means : (a) arrange correctly in accordance with the correct method of doing activities and (b) make thorough preparations so that activities can be done even if they occur abruptly
33 Seiton = Systematic Arrangement How to achieve Systematic Arrangement ? Decide where things belong Decide where things belong Decide how things should be put away Obey the Put away rules
34 Seiton = Systematic Arrangement How to achieve Systematic Arrangement ? Decide where things belong - - Standardize Nomenclature - Determine an analytical method of storage Decide how things should be put away - Name & locations to everything. - Label both item and location - Store material functionally - Prevent mistakes with coding by shapes & colour contd..
35 Seiton = Systematic Arrangement How to achieve Systematic Arrangement ? Decide how things should be put away - - Follow (FIFO) 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
37 Seiton = Systematic Arrangement Usage Frequency Store frequently used material near the workplace and less frequently at some distance Weight & Shape of the Material Heavy material should be stored at lower levels/layers Place directly on the material handling device for ease of handling Functional Storage
38 Seiton = Systematic Arrangement Category Same category of material may be stored in one location. e.g, Allen Screws, Oil Seals Operation Wise All items required for an operation may be stored in one location. e.g, Allen key, spanner etc hand tools required for setting m/c Functional Storage
39 Seiton = Systematic Arrangement Outlining and Placement Marks - - Mark boundaries of dept., aisles, Machines - Follow straight line, right angle rule - Nothing shall be kept outside the boundaries Stands and shelves - - Keep only required number of stands and shelves - Standardize height, size - Provide casters where necessary so that it can be moved
40 Seiton = Systematic Arrangement Wires and Ducts - - Colour code - When there are multiple connections – bundle the wires, label them and make 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 tool should be such that it can be put away with one hand - Try to eliminate some hand tools by permanently attaching it to the bolt head
41 Seiton = Systematic Arrangement Blades, Dies, Other important consumables - - Store 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 they are not mislabeled
42 Seiton = Systematic Arrangement Oils - - 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
3 ‘ S’ - SEISO 3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc
47 SEISO = Cleaning Meaning Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of Inspection 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
48 SEISO = Cleaning Japanese Meaning : Dictionary meaning “to clean up” and “getting rid of dirt and unclean items” While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection Japanese Meaning : Dictionary meaning “to clean up” and “getting rid of dirt and unclean items” While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection
49 Seiso = Cleaning Here cleaning means more than just keeping Here cleaning means more than just keeping things clean. Cleaning should be viewed as a things clean. Cleaning should be viewed as a form of Visual Inspection form of Visual Inspection Preventive measures should be taken to tackle Preventive measures should be taken to tackle problems of dust, grim, burrs, leakage etc. problems of dust, grim, burrs, leakage etc. Root cause of the problem should be identified Root cause of the problem should be identified and it should be eliminated and it should be eliminated
50 Seiso = Cleaning 5 Minutes Every day for cleaning Devote 5 minutes everyday for cleaning your Devote 5 minutes everyday for cleaning your work area work area Participation of everyone is required Participation of everyone is required Attack hard to clean places regularly Attack hard to clean places regularly
51 Seiso = Cleaning SL.NoCHECKLISTTICK 1Check Floors are clean 2Check Work areas are clean 3Check walls are clean 4Check Pillars and Ceiling are clean 5Check Windows are clean 6Check Rooms and Electrical lights are clean EXAMPLE : PREPARE CHECKLIST FOR CLEANING
52 Seiso = Cleaning Seiso Cycle BEFORE WORK, CLEAN AND INSPECT THE MACHINERY TOOLS, JIGS & FIXTURES. BEGINNING OF WORK - DO TRIALS AND START UP DURING OPERATION - CLEAN, INSPECT, DISCOVER AND DEAL WITH ABNORMALITIES AFTER COMPLETION OF WORK - DISPOSE OFF AND GET RID OF UN-NECESSARY THINGS SEISO IS A PART OF GOOD WORKMANSHIP SEISO IS AN IMPORTANT PRE-CURSOR WITH 5S
53 Seiso = Cleaning Cleaning-Inspection points for most equipment equipment Cleaning Grime, clogging, dust balls, rust, leakage etc. Oils No oil, Low oil, leakage, filter clogging, dirty oil, dirty or bent oil lines, clogged drainage, oil spillage, worn& torn ports etc.
54 Seiso = Cleaning Cleaning-Inspection points for most equipment equipment Tightening Loose bolts, welding detachment, loose parts, vibration or bumping noise, friction Heat Oil tanks, motors, heater, axles, control panels, washing/ cleaning water, bearing, wiring etc.
55 Seiso = Cleaning Cleaning-Inspection points for most equipment equipment Breakage, Cracks Breakage, cracks, dent on sliding parts, handle has come off, broken switches, wire joints come off, wires are broken or crack, crack dial of various pre. gauges, meters etc.
56 Seiso = Cleaning Function wise Cleaning check list of equipment equipment Pneumatics Hydraulics Compressed Air lines, air valves, connections, meters, filters, reservoirs etc. Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc.
57 Seiso = Cleaning Function wise Cleaning check list of equipment equipment Mach. & Power Train Electrical Motor fan, fan belt, couplings, Joints, pulleys, chains, pump bearings etc. Control panel, lamps, light, switch, sensors, wiring, ducts, fuses etc.
58 Seiso = Cleaning Function wise Cleaning check list of equipment equipment Tooling Equipment Specific Tools, fixtures, gauges, dies, measuring instruments, etc. Furnaces, rollers, chutes, CNC machines, etc.
4 ‘S’ – In every human being the structure of fingers are same I.e. Standardised. If it is not so, then we call it is abnormal. 4 ‘ S’ - SEIKETSU
63 SEIKETSU = Standardization Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure) Activity - Innovative visual management - Colour coding - Early detection of problem and early action Success Increase in 5S indicator Indicator
64 SEIKETSU = Standardization Japanese Meaning : Dictionary meaning “unsoiled things, purity and cleanliness” Clean manners, Clean cloths, clean politician It is the proof that 3 S’s are being faithfully carried out. Japanese Meaning : Dictionary meaning “unsoiled things, purity and cleanliness” Clean manners, Clean cloths, clean politician It is the proof that 3 S’s are being faithfully carried out.
65 SEIKETSU = Standardization Tools used for analysis : MTTR : Mean Time To Repair \ Recover MTBF : Mean Time Between Failures OEE : Overall Equipment Efficiency Tools used for analysis : MTTR : Mean Time To Repair \ Recover MTBF : Mean Time Between Failures OEE : Overall Equipment Efficiency
66 Seiketsu = Standardization Regularizing 5S activities so that abnormalities are revealed Make it easy for everyone to identify the state of normal or abnormal condition For maintaining previous 3S, deploy visual management
67 Seiketsu = Standardization It has been estimated by scientific study that 60% of all human activities starts with sight 5S is easy to do once. It is consistency that is difficult. That is why Visual Management is so important, so that everybody will know that there is some problem. Visual Management
68 Seiketsu = Standardization What visual control communicates ? It grabs one or more of our senses in order to Alert us to an abnormality Help us recover quickly Promote adherence and prevention Enable successful self management
69 Seiketsu = Standardization Some methods for visual communication Colour coding Use of Labels Danger alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators
70 Seiketsu = Standardization Some methods for visual communication Labels Precision management labels Inspection labels Temperature labels Responsibility labels
71 Seiketsu = Standardization Points to remember in making visual control tools 1. Make them easy to see from distance 2. Put the display on the things 3. Everyone can tell what is right and what is wrong 4. Anybody can follow them and make necessary corrections easily 5. Work place should look brighter & orderly
72 Seiketsu = Standardization Some everyday visual management examples Traffic signal Zebra crossing In car - Petrol indicator - Speed indicator Direction arrows Electric danger sign etc.
73 Seiketsu = Standardization Some visual communication signs
ENSURE... P rocedure & Work Instruction are correct. SS tandard are expressed in specific. VV isual Aids are used. TT rain at all levels. W ork ethics for effective management. T ransparent & Discipline work culture.
5 ‘S’ – Every human body has its standard process which they maintain. 5 ‘ S’ - SHITSUKE
77 SHITSUKE = Self Discipline Meaning Every one sticks to the rule and makes it a habit Activity - Participation of everyone in developing good habits - Regular audits and aiming for higher level Success High employee morale Indicator Involvement of all people
78 SHITSUKE = Self Discipline Japanese Meaning : Dictionary meaning is “learning of the manners” “having manners, dressing neatly” OR “training children for good customs” Japanese Meaning : Dictionary meaning is “learning of the manners” “having manners, dressing neatly” OR “training children for good customs”
79 SHITSUKE = Self Discipline Activities : 5S Committee 5S Training 5S Competition / evaluation 5S Month Posters, Literature etc. Activities : 5S Committee 5S Training 5S Competition / evaluation 5S Month Posters, Literature etc.
80 Shitsuke = Self Discipline We need everyone to maintain 5S guidelines. To maintain DISCIPLINE, we need to practice and repeat until it becomes a way of life. Discipline is the Core of 5S
81 Shitsuke = Self Discipline Discipline means making a steady habit of properly maintaining correct procedure correct procedure. Time and effort involved in establishing proper arrangement and orderliness will be in vain if we do not have discipline to maintain it.
82 Shitsuke = Self Discipline Pledge It shall be my constant effort to It shall be my constant effort to maintain my workplace in good maintain my workplace in good order by order by Assigning a place for everything Assigning a place for everything & keeping everything in its place & keeping everything in its place Sorting out unwanted material Sorting out unwanted material periodically & discarding them periodically & discarding them Keeping my work area neat & Keeping my work area neat & clean everyday clean everyday
83 Organization Departments into areas Coordinators at department level Coordinator at each area level Training for all Audit each area and make action check list Implement actions Audit and evaluation on continuous basis ORGANIZATION