3 What is 5S ?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.
4 5S1. Sort - All unneeded tools, parts and supplies are removed from the area2. Set in Order - A place for everything and everything is in its place3. Shine - The area is cleaned as the work is performed4. Standardize - Cleaning and identification methods are consistently applied5. Sustain - 5S is a habit and is continually improvedAlso - Work areas are safe and free of hazardous or dangerous conditions
5 Some New WordsLean Manufacturing-concepts that seek continuous improvement by removing waste in processesSome Japanese words one need to know: Kaizen-(pronounced “kai zen”) – Continual improvementMuda-(pronounced “moo da”) - wasteGemba-(pronounced “gim ba”) – workplaceKanban-(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.
6 KAIZEN: What it is? Process Improvement Observation Use of New ParadigmsShort TimeZero InvestmentHuman Development & EmpowermentProfits & Savings - Plenty
7 KAIZENKAIZENALWAYSGOODCONTINUALIMPROVEMENTCHANGEFOR THE BETTER
8 KAIZEN IS A JOURNEY FROM: EVENTRESULTGROSSENFORMENT OF CHANGETO CAUSETO PROCESSTO MICROTO INDUCEMENT OF CHANGE
9 CONTINUOUS CONTINUAL KAIZEN IS CONTINUAL IMPROVEMENT TIME TIME
10 KAIZEN: KNOW THE REALITY THROUGH YOUR SENSE OBSERVATIONINTELLIGENCEPHYSICAL EFFORTPARADIGM OF HIGH PRODUCTIVITY & QUALITY
11 KAIZEN AT GEMBA GEMBA: PLACE OF WORK GEMBA is where . . . Value is addedActual work is done to meet customer requirementProblems are solvedStaff is responsible for providing support, not for giving instruction
12 1. 5S Principles Elimination of waste Every body is involved, Co-operative effortAttack root causeHuman being is not infallible
13 2. Objectives Improve housekeeping Make every individual responsible for housekeepingBeautify by simple meansProductivity improvement by saving time, space etc.
14 (Systematic Arrangement) The ‘S’Japanese WordWhat is involvedObjective1SSEIRI(Sorting Out)Segregate necessary from unnecessaryRemove what is not requiredDecide on frequency of sortingSaving and recovering Space2SSEITON(Systematic Arrangement)Arranging in orderPlace for everything, Everything in its placeMinimizing search time3SSEISO(spic and Span)Cleaning the work place/ equipmentAttaining the warning bellInspecting for problemsTaking corrective actions faster4SSEIKETSU(Standardization)Working Methodology(Procedures & WI)Achieving higher productivity and better quality5SSHITSUKE(Self Discipline)Forming the habit in form of Training and DisciplineDoing it right at First Time
16 SEIRI = SortingMeaning Distinguish between necessary and unnecessary items and eliminate the unnecessary itemsActivity Establish a criteria for eliminating unwanted itemsEliminate unwanted items either by disposingthem or by relocating them.Success Area saved or percentage of space availableIndicator
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
18 Respiratory System 1 ‘S’ - SEIRI 1 ‘S’ – Our respiratory system sorts oxygen and other gases And exhales other gases which are unwanted for our body
19 1S – SEIRI : SORTING 1 ‘ S’ Sort for . . . Not Needed at All Needed but not NowNeeded but not hereNeeded but not so much Quantity1 ‘ S’WANTED UNWANTED
20 What is unnecessary Seiri = Sorting 1. Item is not needed 2. Item is needed however quantity in stock is morethan what is needed for consumption in nearfuture3. Contingency PartsCritically decide the quantity of contingencyparts to be retained and criteria for such parts
21 Organization LOW AVERAGE HIGH Frequency of use Storage Method Throw them out*Things you have not usedin the past one yearLOW*Things you have used oncein the last 6-12 monthsStore at distance ORKeep in store*Things you have used onlyonce in the last 2-6 monthsStore it in central placein your zoneAVERAGE*Things used more than oncea monthStore it in central placein your zoneHIGH*Things used once a weekStore near the workplace*Things used daily or hourlyStore near the workplace
22 Identifying unnecessary Seiri = SortingIdentifying unnecessary1. Parts & Work in Process (WIP)Things fallen back behind the machine or rolled under itBroken items inside the machineThings under the racks/ platformExtra WIPStock of rejected itemsItems accumulated over period for reworkMaterial awaiting disposal decisionMaterial brought for some trial, still lying even after trialSmall qty of material no longer in useContd..
23 Identifying unnecessary Seiri = SortingIdentifying unnecessary2. Tools, Tooling, Measuring devicesOld jigs, tools not in use are lyingModified tools, tooling for trial, are lying after trialWorn out items like bushes, liners, toggles etc. lyingBroken tools, bits, etc. may be lyingMeasuring equipment not required for the operationbeing performed , is lying3. Contingency PartsMany times storage place for contingency parts becomea last refuge for broken parts, surplus items and thingsnobody is likely to useContd..
24 Identifying unnecessary Seiri = SortingIdentifying unnecessary4. Shelves and LockersShelves and lockers tends to collect things that nobodyever uses , like surplus, broken items etc.5. Passages and CornersDust, material not required seem to gather in corner6. Besides Pillars and under the stairsThese places tends to collect junk, spittoon etc.7. Walls and Bulletin BoardsOld out dated notices which have lost their relevancePosters or bulletins on wallDust, remains of torn notices, cell tape piecesContd..
25 Identifying unnecessary Seiri = SortingIdentifying unnecessary8.Floor, Pits, PartitionsDefective partsProtection caps, coversPacking materialHardware items , small itemsEven tools, toolingItems dropped on the floor are never picked9.Computer Hard DiskMany unwanted, outdated, temporary files pile up
26 Improvement methods Seiri = Sorting 1. Flow Process Chart (Procedural Analysis)Drawing a process flow chart for the systeme.g. How to make and use category wise grouping2. Operational AnalysisPreparing the sequence of operations for systeme.g. How to perform Seiri (sorting)3. Check ListA check sheet is used to decide what sort of main systemand sub system are necessary.
27 Dealing with papers How to Reduce Papers on Your Table ? Seiri = SortingDealing with papersHow to Reduce Paperson Your Table ?1. Make a single pile of papers2. Go through them and sort infollowing categoriesa) Immediate actionb) Low priorityc) Pendingd) Reading materiale) For information
28 Dealing with papers How to Reduce Papers on Your Table ? 4 D Principle Seiri = SortingDealing with papersHow to Reduce Paperson Your Table ?4 D PrincipleDODELEGATEDELAYDUMP
29 Arranging things in systematic way Seiton : Systematic ArrangementPLACE FOR EVERYTHING,EVERYTHING IN ITS PLACEArranging things in systematic way
30 2 ‘S’ – In our body there is a fixed place for every organ. 2 ‘ S’ - SEITON2 ‘S’ – In our body there is a fixed place for every organ.
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 puttingeverything in its placeSuccess - Time saved in searchingIndicator - Time saved in material handling
32 SEITION = Systematic Arrangement Japanese Meaning:Dictionary meaning of Seiton is “to be correctlyprepared” 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 belongDecide how things should be put awayObey the Put away rules
34 Seiton = Systematic Arrangement How to achieve Systematic Arrangement ?Decide where things belong- Standardize Nomenclature- Determine an analytical method of storageDecide how things should be put away- Name & locations to everything.- Label both item and location- Store material functionally- Prevent mistakes with coding byshapes & colourcontd..
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 aftertheir use
37 Seiton = Systematic Arrangement UsageFrequencyStore frequently used materialnear the workplace and lessfrequently at some distanceHeavy material should bestored at lower levels/layersPlace directly on the materialhandling device for ease ofhandlingWeight &Shape of theMaterialFunctional Storage
38 Seiton = Systematic Arrangement Same category of materialmay be stored in one location.e.g, Allen Screws, Oil SealsCategoryAll items required for anoperation may be stored inone location.e.g, Allen key, spanner etchand tools required forsetting m/cOperationWiseFunctional 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 boundariesStands and shelves- Keep only required number ofstands and shelves- Standardize height, size- Provide casters where necessary so thatit can be moved
40 Seiton = Systematic Arrangement Wires and Ducts- Colour code- When there are multiple connections –bundle the wires, label them and make surethat they are in straight line /right angleand firmly anchored.Machine-tools & Tools- Put the tools in the order you need them- Location of the tool should be such thatit can be put away with one hand- Try to eliminate some hand tools bypermanently 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 byapplying 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 partduring transit, they do not get rusty andthey are not mislabeled
42 Seiton = Systematic Arrangement Oils- Reduce number of oils used (Standardize)- Colour code for oil- Safety aspects - fire prevention,pollution, leak, spillageInstrumentation & Measuring Devices- Label them, show direction of flow
46 3 ‘ S’ - SEISO3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc
47 SEISO = CleaningMeaning Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of InspectionActivity - Keep workplace spotlessly clean- Inspection while cleaning- Finding minor problems with cleaning inspectionSuccess - Reduction in machine down timeIndicator 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
49 Here cleaning means more than just keeping Seiso = CleaningHere cleaning means more than just keepingthings clean. Cleaning should be viewed as aform of Visual InspectionPreventive measures should be taken to tackleproblems of dust, grim, burrs, leakage etc.Root cause of the problem should be identifiedand it should be eliminated
50 Devote 5 minutes everyday for cleaning your work area Seiso = Cleaning5 Minutes Every day for cleaningDevote 5 minutes everyday for cleaning yourwork areaParticipation of everyone is requiredAttack hard to clean places regularly
51 Seiso = Cleaning EXAMPLE : PREPARE CHECKLIST FOR CLEANING SL.No TICK1Check Floors are clean2Check Work areas are clean3Check walls are clean4Check Pillars and Ceiling are clean5Check Windows are clean6Check Rooms and Electrical lights are clean
52 Seiso = Cleaning Seiso Cycle BEFORE WORK, CLEAN AND INSPECT THE MACHINERY TOOLS, JIGS & FIXTURES.BEGINNING OF WORK - DO TRIALS AND START UPDURING OPERATION - CLEAN, INSPECT, DISCOVER AND DEAL WITH ABNORMALITIESAFTER COMPLETION OF WORK - DISPOSE OFF AND GET RID OF UN-NECESSARY THINGSSEISO IS A PART OF GOOD WORKMANSHIPSEISO IS AN IMPORTANT PRE-CURSORWITH 5S
53 Cleaning Oils Seiso = Cleaning Cleaning-Inspection points for most equipmentGrime, clogging, dust balls, rust,leakage etc.CleaningNo oil, Low oil, leakage, filter clogging,dirty oil, dirty or bent oil lines, cloggeddrainage, oil spillage, worn& torn portsetc.Oils
54 Tightening Heat Seiso = Cleaning Cleaning-Inspection points for most equipmentLoose bolts, welding detachment,loose parts, vibration or bumpingnoise, frictionTighteningOil tanks, motors, heater, axles, controlpanels, washing/ cleaning water,bearing, wiring etc.Heat
55 Breakage, Cracks Seiso = Cleaning Cleaning-Inspection points for most equipmentBreakage, cracks, dent on slidingparts, handle has come off, brokenswitches, wire joints come off, wiresare broken or crack, crack dial ofvarious pre. gauges, meters etc.Breakage,Cracks
56 Pneumatics Hydraulics Seiso = Cleaning Function wise Cleaning check list ofequipmentCompressed Air lines, air valves,connections, meters, filters,reservoirs etc.PneumaticsHydraulic oil tank, oil valves,filters, pumps, hoses, gauges,cylinders etc.Hydraulics
57 Mach. & Power Train Electrical Seiso = Cleaning Function wise Cleaning check list ofequipmentMotor fan, fan belt, couplings,Joints, pulleys, chains, pumpbearings etc.Mach. &Power TrainElectricalControl panel, lamps, light, switch,sensors, wiring, ducts, fuses etc.
58 Tooling Equipment Specific Seiso = Cleaning Function wise Cleaning check list ofequipmentTools, fixtures, gauges, dies,measuring instruments, etc.ToolingEquipmentSpecificFurnaces, rollers, chutes,CNC machines, etc.
62 4 ‘ S’ - SEIKETSU4 ‘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.
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 actionSuccess Increase in 5S indicatorIndicator
64 SEIKETSU = Standardization Japanese Meaning :Dictionary meaning“unsoiled things, purity and cleanliness”Clean manners ,Clean cloths, clean politicianIt is the proof that 3 S’s are being faithfullycarried out.
65 SEIKETSU = Standardization Tools used for analysis :MTTR : Mean Time To Repair \ RecoverMTBF : Mean Time Between FailuresOEE : Overall Equipment Efficiency
66 Seiketsu = Standardization Regularizing 5S activities so thatabnormalities are revealedMake it easy for everyone to identifythe state of normal or abnormalconditionFor maintaining previous 3S, deployvisual management
67 Seiketsu = Standardization It has been estimated by scientificstudy that 60% of all human activitiesstarts with sight5S is easy to do once. It is consistencythat is difficult. That is why VisualManagement is so important, so thateverybody will know that there issome problem.Visual Management
68 Seiketsu = Standardization What visual control communicates ?It grabs one or more of our senses inorder toAlert us to an abnormalityHelp us recover quicklyPromote adherence and preventionEnable successful self management
69 Seiketsu = Standardization Some methods for visual communicationColour codingUse of LabelsDanger alertsIndication where things should be putDirectional arrows/ marksTransparent coversPerformance indicators
70 Seiketsu = Standardization Some methods for visual communicationLabelsPrecision management labelsInspection labelsTemperature labelsResponsibility labels
71 Seiketsu = Standardization Points to remember in making visualcontrol tools1. Make them easy to see from distance2. Put the display on the things3. Everyone can tell what is right andwhat is wrong4. Anybody can follow them and makenecessary corrections easily5. Work place should look brighter &orderly
72 Seiketsu = Standardization Some everyday visual managementexamplesTraffic signalZebra crossingIn car - Petrol indicator- Speed indicatorDirection arrowsElectric danger sign etc.
73 Seiketsu = Standardization Some visual communication signs
75 ENSURE . . .Procedure & Work Instruction are correct.Standard are expressed in specific.Visual Aids are used.Train at all levels.Work ethics for effective management.Transparent & Discipline work culture.
76 5 ‘S’ – Every human body has its standard process which they maintain. 5 ‘ S’ - SHITSUKE5 ‘S’ – Every human body has its standard process which they maintain.
77 SHITSUKE = Self Discipline Meaning Every one sticks to the rule and makes it a habitActivity - Participation of everyone in developing goodhabits- Regular audits and aiming for higher levelSuccess High employee moraleIndicator 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”
79 SHITSUKE = Self Discipline Activities :5S Committee5S Training5S Competition / evaluation5S MonthPosters , Literature etc.
80 Shitsuke = Self Discipline We need everyone to maintain 5Sguidelines.To maintain DISCIPLINE, we needto practice and repeat until itbecomes a way of life.Discipline is the Core of 5S
81 Shitsuke = Self Discipline Discipline means making a steadyhabit of properly maintainingcorrect procedure.Time and effort involved inestablishing proper arrangementand orderliness will be in vain ifwe do not have discipline tomaintain it.
82 Shitsuke = Self Discipline PledgeIt shall be my constant effort tomaintain my workplace in goodorder byAssigning a place for everything& keeping everything in its placeSorting out unwanted materialperiodically & discarding themKeeping my work area neat &clean everyday
83 ORGANIZATION Organization Departments into areas Coordinators at department levelCoordinator at each area levelTraining for allAudit each area and make action check listImplement actionsAudit and evaluation on continuous basisOrganization