5s Presentation

Quality Assurance

Necessity of 5S

SEIRI

SEITON SEIKETSUSEISOU

SHITSUKE

Productivity improvement

Quality assurance Cost reduction

Secure production volume

Deadline observation Happy workplace

Job satisfaction

Workplace improvementWorkplace improvement

Quality Assurance

Definition of 5S

(1) SEIRI (Sort)Distinguishing between necessary and unnecessary things, and getting rid of what you do not need

(2) SEITON (Set in Order)The practice of orderly storage so the right item can be picked efficiently (without waste) at the right time

(3) SEISOU(Shine)Create a clean worksite without garbage and dust

(4) SEIKETSU(Standardization)Standardization of best practices

(5) SHITSUKE (Sustain) The practice of developing customs so that the workplace regulations and rules are

correctly practiced

Quality Assurance

Promotion of 5S

(1)

SEIRI(Sort)

Dispose what is not needed

(2)

SEITON(set in order)

Can retrieve when required

(3) SEISOU

(Shine)

Make the workplace clean

(4)SEIKETSU (Standard)Standardized the

solution

(5)

SHITSUKE(Discipline)

Develop customs that allow practice of regulations and rules

Quality Assurance

Objective of 5S

Remove wasteRemove waste

Implement so that ‘waste becomes visible

to facilitate waste removal’

Waste = Current work – money generating workFrom current work remove work that does not generate money

Quality Assurance

5S that Eliminates Waste

Clean

objects Dirty

objects Clean

objects

A little dirty

objects

Dirty objects

Waste (rag) sifting boxes

Quality Assurance

“Self-discipline” is the foundation for success of 5S

““Self-discipline” supports 5SSelf-discipline” supports 5S

Seiketsu(Standardization)

Seiso(Shine)

Seiri(Sort)

Seiton(Set in order)

Sitsuke (Sustain )

Quality Assurance

Heinrich’s Law

Major accident

1 incident

Small scale accidents

29 incidents

Near miss / startling incidents

300 incidents

Accumulation of small details leads to big success

Quality Assurance

StandardizationStandardization

Bolts Sifting and Sorting

Normal 5S

Profitable 5SProfitable 5S

What value is being created ?What value is being created ?

Quality Assurance

SEIRI

Dispose Assign fixed place

SEIRI (Sort) refers to:

Distinguishing between necessary things and unnecessary things and getting rid of what you

do not need

Stratify

Steps

Quality Assurance

Stratification

‘Stratification’ refers to:Assorting things around oneself into those that are required and those that are not required

*Other than things used daily are non-required things

*Quantity in excess of what is used daily is non-required * ‘Leave only this, just in case’ is strictly prohibited

Quality Assurance

Action Standards

Standards Action

Dispose

Things used approximately once in 6 to 12 months Place far away

Things used approximately once in 1 to 6 monthsGather and place together at the worksite

Things used once a week Place in vicinity of work

Things used daily

Place so that they are easy to pickMake it easy to return

Identifiable

Things used every hourPlace within arm’s length where they can be easily reached

Quality Assurance

Categorization of Actions

Category Candidate items for actions

Product, in-process product, components, materials, sub-materials etc.

Machinery, jigs, tools, molds etc.

Old products, components, materials, sub-materials etc.

Drawings, documents, magazines, catalogs etc.

Those that have expiredNon-required items

Those that have become old

Damaged products, non-conforming products, rusted

materials etc.

Things not planned to be used

Things not used for several years

Quality Assurance

Assign Fixed Places

Assigning fixed places refers to:Preparing rules and making visible ‘where’ and in ‘what quantity’’ the required things are to be placed

* Decide locations for things that will remain

* Make rules for locations

* Making visible refers to visual management * Start with what can be done

Quality Assurance

Location of things that will remain

Location of things that will remain should

consider :

(1) Where it will be used

(2) Where it will be placed

(3) How much it will be placed

(4) How it will be placed

Quality Assurance

SEITON

Make it compact

SEITON (Set in order) refers to :Implementing functional storage by deciding correct placement method and layout so that the required objects can be quickly used what it is required

Assign fixed places and fixed quantity

Steps

Quality Assurance

Assign fixed places and fixed quantity

Assigning fixed places and fixed quantity :Refers to facilitating picking and placing and ensuring zero shortages

* Give priority to use frequency and decide fixed place

* Consider also safety (mainly weight) -Place heavy objects at a height where they are easy to pick from

* Eliminate labor required for searching and returning

* Decide placing volume bused on usage volume (1 time, 1 day)

Quality Assurance

Storage Index

Storage index = Steps x Hand operation frequency

* How many steps does it take to walk to the storage

location?

* How many times is it necessary to move the hand to

grip, transport and place the object for storage?

*The storage coefficient will vary according to holding

method, transporting method and placement method

Quality Assurance

Decision standards for fixed positions

(1) Where it will be used Clarification of usage objective and place

(2) Where it will be placedNear where it will be used so that work can be done while walkingStand-up operations

(3) How much will be placed Maximum, Minimum, Order point

(4) How will it be placedEasy to place, Easy to remove (one-touch operation)

(5) Indication of placing location Coloring, boundaries

(6) Recognize visuallyIllustrative indication, component name indication, Quantity indication

(7) Stagnating time is visibleFirst in- First out, Recognize by observing placement date

(8)Decide person in-charge of

supervisionIndicate person responsible

Quality Assurance

Examples of tools sorting (Seiton)

Quality Assurance

SEISO

Take action to prevent dirtiness and its occurrence

SEISO (Shine) refers to :Removal of dirt and by investigating source of dirt preparing countermeasures

Identify source of occurrence

Steps

Quality Assurance

Take Preventive Actions

Actions to prevent dirtiness and its occurrence refers to: countermeasures against source of occurrence include countermeasures (challenge towards common sense) for process methods (defects in processing conditions etc.)

*The basic point is sweeping and cleaning and inspecting

*It is also important to take immediate actions such as placing a cover etc.

* Accumulation of small points will lead to a situation where sweeping is not required

Quality Assurance

SEIKETSU

Make abnormalities visible in management points

SEIKETSU (Standardization ) refers to:Standardization of 5S through ‘visual management’

Grasp vital points for management

Steps

Quality Assurance

Standardization of 5S

(1)

Clarification of vital points for management- What are the minute defects- Basic conditions: Cleanliness, refueling, replace tightly bind fast, dirt,

looseness - Operating conditions: pressure, temperature, time, flow volume, weight, Equipment, jigs and tools, sub-materials

(2) Prepare standards for the conditions

- Objectification of judgment standards for normal versus abnormal- Judgment without using measurement, knowledge, intuition and knack

(3) Judgment standards for abnormalities

- Inspection methods that can be used by anybody- Methods for actions against abnormalities

Quality Assurance

Points for Visual Management

(1) Recognize well even from a distance

(2) There are indicators on items to be managed

(3) Whether good or bad is clear, and anybody can point out

(4) Anybody can use, and convenient if used

(5) Anybody can follow and repair quickly

(6) Use of tools leads to neatness

Quality Assurance

SITSUKE

Innovate to ensure observance

SITSUKE (Sustain ) refers to: Preparation of workplace atmosphere where visual management is properly observed

Check state of observance of standardization of 5S

Steps