Total Quality Management Week # 11 5S Prepared by: Khalid Dahleez Faculty of Commerce – the Islamic University of Gaza This material was collected from different sources Total Quality Management - Spring 2010 - IUG 1 1

Total Quality Management - Spring 2010 - IUG WHAT IS 5S? IN ORDER TO ACHIEVE HIGH LEVELS OF QUALITY, SAFETY,AND PRODUCTIVITY, WORKERS MUST HAVE A CONDUCIVE WORKING ENVIRONMENT Developed by the Japanese Housekeeping System Helps Create a Better Working Environment and a Consistently High Quality Process Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG What is 5S? An easy definition is: Finding a place for everything and putting everything in its place. 5S is also the foundation for Continual Improvement (CI) and Lean implementation. It’s the elimination of waste Everywhere – while adding customer value… It’s a mindset & commitment to achieve a totally waste-free operation that’s focused on your customer’s success… achieved by simplifying and continuously improving all processes Total Quality Management - Spring 2010 - IUG

5S stands for 5 initials of the following Japanese words: 1. Sei-ri (Organization) 2. Sei-ton (Neatness) 3. Sei-so (Cleaning) 4. Sei-ke-tsu (Standardization) 5. Shi-tsu-ke (Self-discipline) 5S ONCSS Total Quality Management - Spring 2010 - IUG 3

Total Quality Management - Spring 2010 - IUG THE 5S PRINCIPLES SEIRI – Organisation/Sort out SEITON – Orderliness/Systemize SEISO – The Cleaning/Shining SEIKETSU – STANDARDIZE SHITSUKE - Sustain/Discipline Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG DISCOVERY OF 5S Thirty years ago researchers started studying the secret of success of Japanese manufacturing companies 5S turned out to be the most impressive "secret" The factories were so well organized that abnormal situations were readily apparent Equipments were so clean and well maintained that any problem such as a loose bolt or leaking oil could be easily seen This passion of cleanliness and orderliness became a hallmark of Japanese organizations Total Quality Management - Spring 2010 - IUG

Seiri = Organization (SORT) means we remove all items from the workplace that are not needed for current production (parts, tools, equipment, etc). Industrial definition: To distinguish between necessary things and unnecessary things, and getting rid of what you do not need. Dictionary definition: To put things in order (or organize them) according to a specific rule or principle. Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG 1. ORGANISATION(SEIRI) Decide what you need Remove unnecessary clutter All tools, gauges, materials, classified and then stored Remove items which are broken, unusable or only occasionally used Key Words: Classification management (Necessary & unnecessary things) Red tag movement For unnecessary things, find their true causes. Total Quality Management - Spring 2010 - IUG

Why is my desk getting messy? Unnecessary Not necessary now, but maybe in the future Necessary Every item on my desk belongs to the gray circle Total Quality Management - Spring 2010 - IUG

Do you throw these things away? Not necessary now, but maybe in the future It works! It has a value! It’s still new! It’s usable! It looks nice! Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG RED TAG RED TAG TECHNIQUE GIVE STAFF RED LABELS ASK STAFF TO GO THROUGH EVERY ITEM IN THE WORK PLACE ASK IF NEEDED & THOSE THAT ARE NEEDED,IN WHAT QUANTITY NOT NEEDED (RED TAG IT ) STORE IN THE RED TAG AREA Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG RED TAG For wavering items PLACE THE SUSPECTED ITEMS IN THE RED TAG AREA FOR ONE WEEK ALLOW THE STAFF TO REEVALUATE THE NEEDED ITEMS AT THE END OF WEEK THOSE WHO NEED ITEMS SHOULD BE RETURNED Total Quality Management - Spring 2010 - IUG

Typical Seiri Activities 1. Eliminate defects and breakage 2. Organize the warehouse Before After Total Quality Management - Spring 2010 - IUG T. Sugiyama “The 5S Approach to Improvement” PHP, 1995

Seiton = Neatness - Orderliness - Set in Order Dictionary definition: Establishing a neat layout so that you can always get just as much of what you need when you need it. Industrial definition: It is a way of eliminating search. ONCE YOU HAVE ELIMINATED ALL THE UNNEEDED ITEMS NOW TURN TO THE LEFT OVER ITEMS Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG Question When you ask someone to bring a hammer, how long can you wait without getting mad? How long is your patience? 5 minutes? 2 minutes?? or 5 seconds??? Organise layout of tools and equipment: Designated locations Use tapes and labels Ensure everything is available as it is needed and at the “point of use” Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG 30 Second Rule Workplace 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? Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG Key Words & Typical Activities Key Words: Design an efficient layout (Functional storage) Eliminate search (Less search) Everything should have a name. (A place for everything and everything in its place) Typical Seiton Activities: Stripes on files First in, first out Easy to read notices Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG 3. SEISO (CLEAN/SHINE) Create a spotless workplace Identify and eliminate causes of dirt and grime – remove the need to clean Sweep, dust, polish and paint SHINE means we sweep floors, scrub machines, apply a fresh coat of paint, and then we KEEP it that way. This way, everything will be in top working condition so that it may be used when it is needed. It also means preventive maintenance. Definition: Eliminating trash, filth, and foreign matters for a cleaner workplace. Cleaning as a form of inspection. Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG Key Words: Keep things clean + Inspection (Caring attitude) Divide areas into zones Define responsibilities for cleaning Tools and equipment must be owned by an individual Focus on removing the need to clean Total Quality Management - Spring 2010 - IUG

Cleanliness is a big business today. Sanitation engineers Laundry Dry cleaner Janitor Garbage collector Pollution control operator Clean-room designer One-third (1/3) or one-fourth (1/4) of the total investment amount is used for cleanliness. Total Quality Management - Spring 2010 - IUG

4. SEIKETSU (STANDARDISE) Generate a maintenance system for the first three Develop procedures, schedules, practices Continue to assess the use and disposal of items Regularly audit using checklists and measures of housekeeping Real challenge is to keep it clean Total Quality Management - Spring 2010 - IUG

Seiketsu = Standardization Definition: Keeping things organized, neat, and clean, even in personal and environment aspects. SEIRI SEITON SEISO Total Quality Management - Spring 2010 - IUG

Seiketsu = Standardization Ideal State Current State GAP Define an ideal state Standardize the solution (5S standardization) Total Quality Management - Spring 2010 - IUG

Typical Seiketsu Activities 1. Make quality manual 2. Directional markings 3. Color-coded pipes STANDARDIZATION happens when the first three S’s are properly implemented and maintained. It means that racking, paint colors, labeling, operational layouts are designed in a standard fashion. Everything will be in place so everyone will know exactly what they are responsible for; and, exactly when, where, and, how to do it. Total Quality Management - Spring 2010 - IUG

5. SHITSUKE (SUSTAIN / DISCIPLINE) Means inoculate courtesy & good habits Driving force behind all 5S Deming’s point number 1: Constancy of purpose Make it a way of life Part of health and safety Involve the whole workforce* Develop and keep good habits Total Quality Management - Spring 2010 - IUG

Shitsuke = Self-discipline Definition: Doing the right things as a matter of course. We SORT areas. We SET IN ORDER work places. We SHINE areas. With STANDARDIZATION it is easy to identify anything out of place. SUSTAIN is different: It isn’t a single separate activity; We SUSTAIN when we have developed habits of always using the first 4 S’s together on a daily basis. Total Quality Management - Spring 2010 - IUG

Key Words & Typical Activities Habit formation (Make it a habit) Create a disciplined workplace Typical Shitsuke Activities 1. Wear your safety shoes 2. Exercise time 3. No smoking at workplace Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG WHAT U HAVE COME ACROSS Followings can be harnessed form the 5S NEAT & CLEAN WORKPLACE SMOOTH WORKING NO OBSTRUCTION SAFETY INCREASES PRODUCTIVITY IMPROVES QUALITY IMPROVES WASTAGE DECREASE MACHINE MAINTENANCE VISUAL CONTROL SYSTEM EMPLOYEES MOTIVATED WORKSTATIONS BECOME SPACIOUS Total Quality Management - Spring 2010 - IUG

5 S’s Eliminate Waste Sort Clear out rarely used Items by Red Tagging Straighten Organize and Label a Place for Everything Sustain Use Regular Management Audits to Stay Disciplined Eliminate Waste Shine Clean It Standardise Create Rules to Sustain the first 3 5’S Total Quality Management - Spring 2010 - IUG 29

Total Quality Management - Spring 2010 - IUG When Does 5S Happen? ALL THE TIME!! 5S is a mindset and a culture. The 5S’s are a part of each Associate’s workday. There will also be CI Events and WPO (WorkPlace Organization) Events. In an Event, Associates are taught how to implement the principles of Continual Improvement. Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG How is 5S Implemented? By the associates! Who has a better idea to make our jobs easier than us? Our management is committed to improving how we work. We want to work smarter, not harder. Along the way, support will come from EVERYONE. We will teach the 5S process, and together we will implement it and make it work. Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG ADVANTAGES OF 5S If tools and materials are conveniently located in uncluttered work areas Operators spend less time looking for items This leads to higher workstation efficiency, a fundamental goal in mass production A clean and tidy workplace leads to greater well being and increased motivation Company image improves Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG ADVANTAGES OF 5S Health and Safety is ensured Machine maintenance Quality Productivity Lean Manufacturing TIME SAVING QUICK RETRIEVAL ACCIDENTS & MISTAKES MINIMIZED INCREASES SPACE CREATES WORKPLACE OWNERSHIP Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG ADVANTAGES OF 5S RESULTS IN A PLACE EASIER TO MANAGE SMOOTH WORKING NO OBSTRUCTION NO DEVIATION, NO PROBLEMS B/C EVERYONE KNOWS WHERE THE THINGS ARE SPPOSEDF TO BE Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG ADVANTAGES OF 5S FOUNDATION OF ALL QC TOOLS CONTINUOUS QUALITY IMPROVEMENT LEAN MANUFACTURING KINDERGARTEN OF QUALITY TOOLS & TECHNIQUES Total Quality Management - Spring 2010 - IUG

Total Quality Management - Spring 2010 - IUG ADVANTAGES OF 5S VISUAL MANAGEMENT SYSTEM VISUAL CONTROL TO SEE THE ABNORMALITIES SIMPLE SIGNALS THAT PROVIDE AN UNDERSTANDING OF THE CONDITION( NORMAL/ ABNORMAL) A LOOK AT THE PROCESS REVEALS ITS DIRECTION (RIGHT/WRONG) Total Quality Management - Spring 2010 - IUG