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5 S

MANAGEMENT SYSTEMDate :- 24 Oct 10

By

Mahesh Limaye

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Copyright 2007 Larsen & Toubro Limited. All Rights Reserved.

Definition

5 S is a tool for WASTE ELIMINATION

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Different wastesDefect

Over production

Waiting

Not utilizing persons talentsTransportation / material handling

Inventory

Motion

Excessive processing

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Needs for a product or service

Quality

Safety

AvailabilityDelivery

Variety

Cost

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Major CPI

Tools (6s) Kaizen Lean Description

Cp/Cpk 4 Process capability assessment

DOE 4 Design of experiments

SPC 4 Process control based on statistics and data analysis

FMEA 4 Risk assessment tool

Regression 4 Correlate effect one variable has on anotherProcess Map 4 4 4 Map process steps to communicate and identify opportunities

5 whys /2 hows 4 4 4 Determination methods for root cause discovery

Pareto 4 4 4 Column chart ranking items highest to lowest

Fishbone 4 4 4 Cause / Effect Diagram

5S 4 4 Elimination waste

Visual Mgmt 4 4 4 Emphasis on visual techniques to manage process

Poka-Yoke 4 4 Error proofing techniques

Spagetti Chart 4 4 Product / people / paper flow mapping

Kanban 4 4 Material storage technique used to control processTakt Time 4 4 Determine pace or beat of a process

Std Work 4 4 Evaluate tasks done during a process

SMED 4 4 Single minute exchange of dies - Quick machine set up

TPM 4 Integrate maintenance strategy with process

Cellular Flow 4 Reduce inventory & cycle time thru process layout and pull

production techniques

Tool Kit Comparison

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5 S lays foundation forClean workplace improved safety & productivity

Making problems Visible

Create space for new activity

Continuous Process ImprovementPositive perception of members & outsiders

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What is 5S5S Original

Japanese

Meaning in English

1S SEIRI

(Segregation)

Sort out unnecessary items in the workplace and

discard them

2S SEITON(Arrangement)

Arrange necessary items in good order so thatthey can be easily picked for use

A place for everything

Everything in its place

3S SEISO

(Clean) Clean your workplace thoroughly so that there isno dust on floors, machines and equipments

4S SEIKETSU

(Standardize)

Maintain high standards of workplace at all times

5S SHITSUKE

(Discipline)

Train people to follow good housekeeping

discipline automatically 7/20

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First S - Seiri : SegregateACTIVITIES

1. Go through what you have

2. Segregate/identify what youneed

3. Categorize needed / not

needed items4. Discard What Is

Unnecessary

5. Establish a well defineddisposal system

INDICATOR OF SUCCESS

1. Decrease in unnecessaryitems and reserve stock

2. Percentage of area / space

saved 8/20

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First S - Seiri : Segregate

Removal of unwanted material from

workshops and offices

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Second S - Seiton : ArrangeACTIVITIES

1. Set things in order by

creating a place for

everything.

2. Put everything in its place

3. Keep accessibility as easy

as possible.

4. Use the principle of wide

range and shallow depth for

storage.SUCCESS INDICATORS

1. Time saved in searching

2. Time saved in handling

material

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Second S - Seiton : Arrange

Putting inorder

Thingsneeded

Things usedConstantly

Place as closeas possible

Things usedoccasionally

Place a littlefurther

Seldom usedBut stillneeded

Enclose in a separateDesignated

Place

Things notneeded

PotentiallyUseful

Consider whereuseful

and move todesignated place

No potentialuse

Disposal aftercareful

analysis

How to promote

good order

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Second S - Seiton : Arrange

Arrangement

of Tubes

boxes

Files

Lifting

tackles

& storage racksPEEP Place forEverything

& Everything in its Place

Offices

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Third S - Seiso : CleanupACTIVITIES

1. Clean equipment, tools,

furniture, records, etc.

2. Keep the workplace spotless

3. Sweeping, wiping, polishing,painting, etc.

SUCCESS INDICATORS

1. Reduction in machine

downtime

2. Increased life of the machineparts

3. Reduction in number of

accidents

4. Reduction in rejection /

rework

Neat &

Clean office

And pantry

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Third S - Seiso : Cleanup5 Levels of Housekeeping

1. Horizontal surfaces / floor full of unwanted material.

2. Vertical surfaces / areas near walls having clutter.

3. Horizontal, vertical surfaces clean and have no unwanteditems. However, storage areas, record rooms disorganized.

4. Storage areas, machines, offices are clean. All materials,furniture, documents properly organized, labeled andnumbered.

5. Factory / office is immaculate at all times

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Fourth S - Seiketsu : Maintain StandardsActivities

1. Create standards andinitiate steps to maintainthem

2. Devise ways to

a. Expose hidden problemsb. Surface abnormalities

3. Create visual controlsystems

SUCCESS INDICATORS

1. Number of areas / coversmade transparent

2. Number of new problemsexposed and solved

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Fourth S - Seiketsu : Maintain StandardsStandardizedBuilding Signage

Workshop signanges

Emergency

evacuation plan

& emergency

telephone

numbers

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Fifth S - Shitsuke :DisciplineACTIVITIES

Create general awareness

about 4S

Training to everyone

Share success to get moreenthusiasm

SUCCESS INDICATORS

High employee morale

Involvement of people in themovement

Efforts to make discipline ..a way of life !

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SustenanceCommitment from the top leadership

Participation from all people in the organization.

Allot a day and time for the activity

Understanding of following:

1. A clean workplace is high in PRODUCTIVITY

2. A clean workplace has high QUALITY

3. A clean workplace keeps COST down

4. A clean workplace ensures DELIVERY on time

5. A clean workplace is SAFE for people to work6. A clean workplace is high in MORALE

The program would be more effective when it isincluded in the small group activities

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Excellence through 5S

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THANK YOU

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