Transcript
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5 S + 1S HOUSE- KEEPING
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5-S: HOUSE-KEEPING
1. SEIRI SORTING2. SEITON ARRANGING3. SEISO CLEANING4. SEIKETSU MAINTAINING5. SHITSUKE SELF
DISCIPLINE+1. SHITTSUKOKU SUITABLE
WORKING ENVIRONMENT
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FEATURE OF 5S 5S SUPPORTS ISO 9000/TQM SYSTEM
A DIRTY FACTORY CANNOT PRODUCE QUALITY PRODUCTS
AN ORDERLY ENVIRONMENT PROMOTES AN ORDERLY MIND
CLUTTER HIDES PROBLEMSA CLEAN WORK PLACE EXPOSES PROBLEM5S FACILITATES CONTINUOUS IMPROVEMENT
5-S IS NOT FACTORIES ALONG IT IS ALSO FOR OFFICES AND HOMES
AS WELL
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OBJECTIVES BEHIND 5S QUALITY IMPROVEMENT ACCIDENT\INCIDENT PREVENTION POLLUTION PREVENTION PRODUCTIVITY IMPROVEMENT COST REDUCTION ENERGY CONSERVATION DOWNTIME PREVENTION WORKING ATMOSPHERE PRESERVATION OF ENVIRONMENT MORALE BOOSTING ENCOURAGING CREATIVITY EMPLOYEE PARTICIPATION DEVELOPS SELF-DISCIPLINE BRING CHANGE-IN-ATTITUDE FEEL ENJOY WORKING
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SUGGESTED APPROACH FOR 5S IMPLEMENTATION
IDENTIFY THE WORK PLACE/AREA OF IMPROVEMENT DIAGNOSIS THE PLRESENT STATUS AS PER 5S BRING OUT THE WEAK AREA DETERMINE HOW TO CORRECT ESTABLISH REMEDIAL ACTION
ESTABLISH RECURRENT PREVENTIVE ACTION
ASSIGN INDIVIDUAL ACTIONS RECOGNIZE OWN RESPONSIBILITIES IMPLEMENT CORRECTIVE ACTION VERIFY IF ACTIONS ARE EFFECTIVE LOOK FOR OTHER BETTER IDEAS
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SUGGESTED APPROACH FOR 5 S IMPLEMENTATION
IDENTIFY AND EXPOSE THE WEAK AREA HOW UNTIDY HOW DISORDER HOW INEFFICIENT HOW MUCH DIRTY HOW MUCH MESSY HOW SMEARED HOW RUSTED HOW DUSTY HOW ILL SMELLED HOW MUCH NOISY HOW MUCH DARK HOW MUCH LEAKY HOW MUCH SMOKY HOW MUCH BUSHY HOW MUCH JAM-PACKED
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ADVANTAGES OF 5S IMPLEMENTATION
= WORK PLACE BECOMES CLEAN AND BETTER WORGANISED- SHOP FLOOR AND OFFICE OPERATION
BECOMES EASIER AND SAFER RESULTS ARE VISIBLE TO EVERY INSIDER AND
OUTSIDER VISIBLE RESULTS ENHANCE GENERATION OF MORE AND NEW IDEAS
PEOPLE BECOME PROUD OF CLEAN AND ORGANISED WORK PLAC RESULTANT GOOD COMPANY IMAGE
GENERATES MORE BUSINESS MIND GETS FREE FLOW OF THOUGHTS
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OBJECTIVES OF SEITON
REDUCE PREPARATION AND TOOL SETTING REDUCE TIME SPEND WAITING FOR PARTS MATERIALS, PAPERS AND FILES REDUCING PROCESSING TIME AND CYCLE TIME BY IMPROVING
THE PLANT LAYOUT OF THE WORKSHOPTIME AND ENERGY SPENT ON LOOKING FOR JIGS, FIXTURES,TOOLS,ETC.
HUNTING FOR PARTS IN STORES SEARCHING FOR FILES AND INFORMATION
IN COMPUTERS
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STEPS FOR IMPLEMENTATION OF SEIRI & SEITON MAKE SPOT INSPECTION & ANALYSIS REGARDING UN-NECESSARY & EXTRA ITEMS GET RID OF UNNECESSARY THINGS, PROVIDE MINIMUM ADDITIONAL STORAGE FACILITIES DECIDE WHAT WILL BE STORED WHERE- PLACE FREQUENTLY USED ITEMS NEARBY AND IN-FREQUENTLY USED ITEMS IN SEPARATE PLACE. LABEL STORAGE AREAS IN ORDER TO RETURN TO DESIGNATED LOCATION NUMBER RECORD STORAGE PLACE IN DIRECTION CHART REVIEW AND INSPECTION
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ADDITIONAL TECHNIQUES WHICH CAN BE USED FOR DOING SEIRI AND SEITON
SEIRI AND SEITON PROCESS FLOW CHART PROBLEM SOLVING PROCESS BRAIN STORMING’POKE-YOKE BENCH MARKING CAUSE & EFFECT DIAGRAM CASE STUDY FROM YOUR WORK AREA SELECT A LOCATION FOR
DOING SEITON BRIEFLY DESCRIBE THE PRESENT POSITION AND THE
LOSSES OCCURING DUE TO THIS IDENTIFY THE CAUSES FOR THESE LOSSES WHAT IMPROVEMENT YOU CAN SUGGEST WITH THE
NEW ARRANGEMENT
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5S - SEISO - CLEANING DEFINITION:
REMOVAL OF GENERATED TRASH AND DIRT FROM THE MACHINERY AND TOOLS IN ORDER TO PLUT ITEMS IN THEIR ORIGINAL STATE.
REMOVAL OF SCRAPL, LEFT OVER MATERIALS AND OTHER UN-NECESSARY THINGS WHICH ARE THE RESULTS OF WORK
GET RID OF BAD AND UN-CLEAN THINGS AND PURIFYING TO CLEAN UP EVERY THING IN THE WORK PLACE CONCEPT: TO CARRY OFF OR CLEAR AWAY WITH DRIVING MOVEMENT
OR TO COLLECT, REMOVE OR CLEAR AWAY WITH A BROOM,
BRUSH,ETC. TO ELIMINATE ANY DIRT OR DUST IN THE WORKSHOP AND
TO SUSTAIN NON-SMEARING/STAIN/DIRTNESS CONDITIONS. TO CLEAN YOUR WOPK PLACE COMPLETELY A CLEAN MACHINE ENSURES GOOD QUALITY, IS LESS
LIKELY TO BREAK DOWN AND WILL LAST LONGER. REGULAR CLEANING OF EQUIPMENT AND MACHINES HELP
US TOSLOT PROBLEMS BEFORE THEY BECOME SERIOUS.
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FEATURES OF SEITON ITEMS WHICH ARE NECESSARY ARE PLACED SO THAT
THEY CAN BE FOUND AND GOT EASILY CONTAINER IS CREATED TO KEEP CORECT ITEM
SAFELY AND IN THEIRPROPER ORDER
THINGS CAN BE MOVED AND TRANSPORTED AT ONE TIME TOGETHER
PLACED IN CONTAINER THINGS ARE ARRANGED SO THAT THEY ARE USED EASILY IN ORDER OF USE AND ARE WITHIN REACH
LABELS ARE ATTACHED SO THAT ITEMS CAN BE RECOGNIZEDAT A GLANCE AND CLEAR
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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
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SEISO- INSPECTION
SEISO- INSPECTION SEISO IS NOT ONLY MAKING THINGS
LOOK CLEAN BUT LOOKING AT AND TOUCHING EVERY PART OF THE FACILITY DURING CLEANING
SEISO IS TO REVEAL POTENTIAL DEFECT SUCH AS ABRASION, DAMAGE,
LOOSE PARTS, DEFORMALITIES, LEAKS, TEMPERATURE, VIBRATIONS, ABNORMAL SOUNDS, ETC. AND HENCE SEISO IS INSPECTION
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SEISO CAN DETECT LOOSE BOLT AND SCREWS
LOOSE AND BROKEN ELECTRICAL WIRE CONNECTIONS
CRACKS AND WEAR AND TEAR IN HOSES LEAKAGE IN PIPELINES OIL OR AIR LEAKAGES LOOSE HANDLES LOOSE INSTALLATION OF LIMIT SWITCHES RUST OR DAMAGE TO SLIDING PARTS DISLOCATION OF SAFETY GUARDS DIRTY AIR FILTERS DIRTY OIL GUAGES AND INSUFFICIENT OIL CHUTES CHOKED WITH CHIPS CRACKS IN METER GLASS
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CASE STUDY CASE STUDY FOR ONE OF YOUR WORK AREA
PREPARE A SEISO SCHEDULE FOR CLEANING AND INSPECTION
LIST THE ADVANTAGES EXPECTED
OUT OF THIS SCHEDULE
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4 S - SEIKETSU / MAINTAININGCONCEPT to maint. high standard of Housekeeping and work
place organisation at all times. To think of ways to prevent work place from becoming dirty.
Work clothes, hats, safety shoes, apron, gloves, hair, beards, nails, mechanical
facilities, jigs, tools, materials, containers, trolleys, conveyers, pipes, rooms, floors,
aisles, ceiling, etc. No waiting, no breakdowns, no waiting, Minimum of
incomplete items, on schedule, Production, no late coming/absenteeism, no
searching, no missing parts/papers, no waste of time, no loss of revenue, etc.
to main high standard of Housekeeping and work place organisation at all times.
– CONTD..
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4 S - SEIKETSU / MAINTAININGCONCEPT – contd. From pre-page
To think of ways to prevent work place from becoming dirty. Work clothes, hats, safety shoes, apron, gloves, hair, beards, nails,
mechanical facilities, jigs, tools, materials, containers, trolleys, conveyers,
pipes, rooms, floors, aisles, ceiling, etc. No waiting, no breakdowns, no waiting, Minimum of incomplete
items, on schedule, Production, no late coming/absenteeism, no searching, no missing
parts/papers, no waste of time, no loss of revenue, etc.
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OBJECTIVES
Achieving good house-keeping
Emphasis on prevention
Prevent items from getting dirty
Check points and time schedules
Fix accountability Perfect implementation
of seiri, seiton, seiso continuously
Making comfortable working environment
CASE STUDY Develop an Action Plan for
Maintaining the
STEPS OF SEIKETSU/MAINTAINING
Objects inspection Check list/recording Definition and degree of each
disorder Identify tools and equipments Setting themes for
improvement Avoiding disorders and
breakdowns Daily seiketsu maintenance
system Emergency seiketsu
maintenance system Minor servicing
Seiri, Seiton, Seiso through Seiketsu assigning responsibilities suitably
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5 S - SHITSUKE/ SELF-DISCIPLINE CONCEPT: To have employees habituate for correctly following
procedures specified Morales. Complying with work place rules and methods and maing this a
Habit. A natural attitude to be developed for this This attitude to act as a knitting thread to maintain the other 4S. Vital to strictly control time and absence Wearing helmets, safety shoes, uniforms, name plates, etc. Keeping oneself clean, neat and disciplined. to train people to follow good housekeeping discipline on their own to achieve self reliance and self discipline through continuous and
daily pratics. Rules and method for 4S Control items are strictly obeyed Improvements are promoted Get rid of source of trouble and disorder It is like a power source behind all activities of the 4S - Seiri,
Seiton, Seiso and Seiketsu Even minor greeting at the beginnig and end of the day Operational reports on time There should be horizontal and vertical communication
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CASE STUDY:
Select a theme and sub-theme Analyse the problem Draw cause and effect diagram for
each problem point Develop improvement action plan Evaluate the results
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+1S SUITABLE WORK ENVIRONMENT
It is required to minimize risk to employees to improve business performance to establish a responsible image in
market it is a requirement of employees customers/clients contractors/suppliers community share holders
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IT TAKES CARE OF Noise Ventilation Illumination Hazard identification and control Fire protection Waste disposal Emergency preparedness Plan layout and area classification Communication systems First aid box maintenance CASE STUDY dentify the unsuitable working environment in one of the
selected work area And develop an Action Plan to bring them under control with responsibility and time schedule
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5 S GOOD HOUSE-KEEPING - AUDIT
PREPARE AN AUDIT CHECK LIST FOR THE 5 S + 1 S ACTION PLAN FOR IMPLEMENTATION FORCE FIELD ANALYSIS LIST THE FAVOURING AND RESTRAINING
FORCES DEVELOP AN ACTION PLAN FOR
IMPLEMENTATION OF 5S IN YOUR ORGANISATION ALONG WITH RESPONSIBILITY AND TARGET DATE.
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