5S Improvement

Lean Manufacturing

PRESENT BY : PRAVIN N

PRAJAPATI

Lean Manufacturing..

"lean” is a systematic method for the elimination of waste within a manufacturing system.

Simply Lean Means.. Creating more value for customer with fewer resources.

The Ultimate goal is to provide perfect value to customer through a perfect value creation process that has zero waste.

List of lean tool…. 5S Andon Bottleneck Analysis Continuous Flow Gemba (The Real Place) Heijunka (Level Scheduling) Hoshin Kanri (Policy Deployment) Jidoka (Autonomation) Just-In-Time (JIT) Kaizen (Continuous Improvement) Kanban (Pull System) KPIs (Key Performance Indicators) Muda (Waste)

Overall Equipment Effectiveness (OEE) PDCA (Plan, Do, Check, Act) Poka-Yoke (Error Proofing) Root Cause Analysis Single-Minute Exchange of Dies (SMED) Six Big Losses SMART Goals Standardized Work Takt Time Total Productive Maintenance (TPM) Value Stream Mapping Visual Factory

Types of Waste or Muda

1. Overproduction2. Inventory3. Waiting4. Motion 5. Transportation6. Defects7. Over processing

Reason for implement 5S

Improved Safety - No item on floor - Safety device in their right place - Less dust - Better overview

Reason for implement 5S

Improved Safety Fewer breakdown - less dust from dust or grit in moving part. - fewer error

Reason for implement 5S

Improved Safety Fewer breakdown Better work environment - A clean work place - Fix unsafe work place

Reason for implement 5S

Improved Safety Fewer breakdown Better work environment Fewer human error - Small but anything fault are fixed - It should be easier to do right

Reason for implement 5S

Improved Safety Fewer breakdown Better work environment Fewer human error May find problem earlier - when you clean a machine you inspect at same time

Reason for implement 5S

Improved Safety Fewer breakdown Better work environment Fewer human error May find problem earlier No Searching - Effective tools at the right place

Indirect gains with 5S

Practical training in lean for leaders & Workers.

Better impression in global market.

Easier to recruit good people.

What is 5S ?

The purpose of 5S is to promote a safe & efficient work environment 5S is a method that uses five Japanese word which start with “S” Seiri – Sorting Seiton – Set in order Seiso – Shining (Clean) Seiketsu – Standardize Shitsuke – Sustain

Procedure…

1S : Sorting

Sorting has two main purpose - Remove unnecessary objects - Reduce waste

Go through the whole plant - Machine & Control centre - Works area - Storage and common area

1S : Sorting

Remove unnecessary objects

Look for.. Material - Behind or under machine - Rejected - “Forgotten” material

1S : Sorting

Remove unnecessary objects

Look for.. Material Tool - Not in use - Worn out / Broken

1S : Sorting

Remove unnecessary objects

Look for.. Material Tool Spare parts - Broken - Surplus inventory - Spare part for machine no longer in use

1S : Sorting

Remove unnecessary objects

Look for.. Material Tool Spare parts Out of date document - Files - Manuals - Computer temp. file Other Stuff

Red tag for 5S

2S : Set in Order

Arrange and mark the location of the all objects Organize remaining items

2S : Set in order -- PlacementItem

Very rarely use Long intervals between use

Frequently use

Can be placed outside Work room Placed Near the Machine Place closer to user location

Floor Marking

Agree on a colour code Visualize

Work Surface Safety Zones Machine Surface Transport surface

3S : Seiso – Shine (Clean) Clean the workspace and all equipment,

and keep it clean tidy and organized.

At the end of each shift, clean the work area and be sure everything is restored to its place.

Identify and eliminate causes of dirt and grime – remove the need to clean

Carry out regular cleanliness inspections.

4S : Seiketsu - Standardize

Simplify the way of maintaining cleanliness.

Develop procedures, schedules, practices.

Continue to assess the use and disposal of items.

All employees doing the same job should be able to work in any station with the same tools that are in the same location in every station.

4S : Seiketsu - Standardize

Try to eliminate the problem.

Implement daily routines

Implement weekly procedure

Use a planning system

Planning Boards

5S : Shitsuke - Sustain

To maintain 5S, we need the discipline to practice and repeat until 5S become a way of life.

Visualization Board This is our area This is how it should look This is how we take care of our area. This is how we want to improve our area. This is how we make sure that the routines are being followed.

5S : Shitsuke - Sustain

Audits :Schedule regular audits Ex.:

Each Week – Team leader Each Month - Supervisor Every two month – Higher management

Thank You