Training- 5S

Picture -1 Picture -2

Look at these two pictures ?

Which Picture shows Good Workplace ?

Which Picture shows Clean Workplace?

Which Picture shows Organized Workplace?

Which Picture shows Good Arrangement?

Which Picture shows unneeded items?

Which Picture shows, less time require to find things?

Which Picture shows, tidy workplace?

Definitely Picture - 2.

But How it can be achieved?

This is achieved by a method,

to organize the Workplace,

Called as 5S.

What is 5S ?

5S is a Philosophy and a way of organizingand managing the workspace and workflow.

The intent of 5S is to improve efficiency by eliminating waste, improving flow and

reducing process unevenness.

It uses five Japanese Words, which are converted and translated

Into English, start with letter S.

5S sometimes incorrectly referred asHousekeeping or Cleaning,

whereas

It is more than Housekeeping/Cleaning

5 S

towards

ideal

shop floor

Seiri – 1S

Seiton – 2S

Seiso – 3S

Seiketsu – 4S

Shitsuke – 5S

5S First s – Sort known as Seiri

5 Stowards

ideal

shop floor

– Remove all items from the workplace that are not needed for current operations.

When it is needed

In the amount needed

– When in doubt, throw it out!

What is needed

1. Discard what is unneeded

This involves identifying unneeded from stocks,around machines, from cupboards, documents, from workstation, from warehouse and storages, from office.

2. Classify the needed things

This involves organising a classification of objects using labels identifying their frequency of use: these labels are to be positioned when the initial cleaning is taking place.

5 Stowards

ideal

shop floor

5S Second s – Set in Order known as Seiton

5 S

Organize

Arrange needed items so that they are– Easy to use – Easy to find– Easy to put away

Do not place heavy objects high up.

Easy to pick up,easy to put back,

easy to do.Place the most usedobjects at a height

between theshoulder and the

elbow

Make shelves appropriate to

the size and weight that will

be placed there.

CorrectIncorrect

Define how to order the objects

Define how to order the objects

equipment on wheels: define the position by color and write the name of the vehicle.

as a general rule, indicate the position of everything that has to be moved, so as to be able to replace it more easily.

Mark the position of the objects (marks, labels, ......)

Do not leave containers directly on the floor

use a platform: the parts will not be soiled, and corrosion and knocks can be avoided.

Define how to order the objects

parts box

Platform

Access difficult

Access easy

Avoid placing things too far back as it makes them difficult to reach.

Plan strategies to make organisation easy

Marking makes it possible to replace documents exactly in order

Badly placed

Well placed

Define how to order the objects

This functional order must be organised with the help of the operators, who can make proposals to the 5S work group.

This will ensure:

greater safety

improved quality of parts made

no time wasting

Indicate the part names

Heightlimit

On the platform

Area line

Indicate the quantity and the name of the container

Mark the area according to

the size of the containers

Define how to arrange the objects

Plan a clear system for positioning giving maximum information in a minimum of time

Define how to order the objects

Correct

Incorrect

Draw very legible marks in the installations to make inspection easier.

5S Third s – Clean -(Spic and Span) known as Seiso

5 Stowards

ideal

shop floor

Clean everything

– Sweep floors

– Wipe machinery and equipment

– Paint and repair

– Remove cob webs

– Washrooms

– Under the machine/Behind the machine/Inside of machine

– Oil spillage on the floor, from the machine

– Waste Bins

– Material Bins

– Office equipments and accessories like Computers, Desk, chair etc

– Building Structural Parts like Columns, Beams.

– Pipelines (Clean and Paint)

– Repair and maintain machines, equipments, furniture, lights, floors,

stairs, windows, doors, glass, signages and other structures etc.

- Maintain garden

Rag

Brush

Bleach

Sweeping brush

Vacuum cleaner

Paint

Paint brush

Other equipment

Spic and Span

Use Cleaning equipments for cleaning

5S Four s – Keep the work place clean every time (Standardize) known as Seiketsu

5 Stowards

ideal

shop floor

Prevents problems

Standardized Cleanup

Establishing a method to maintain the first three pillars

Everyone’s responsibility

Define the operational cleaning procedures. (SOP’s & WI for cleaning)

Define the cleaning plans and post them where they can easily be seen on the workstation.

These plans must define:

the place to be cleaned

the means to be used

the time to be devoted to it

how often the cleaning have to be carried out

who has to clean

Standardized Cleanup

5S Fifth s - Maintain – Self Decipline known as Shitsuke

5 Stowards

ideal

shop floor

Discipline

– Making order and cleanliness a habit

– Establish a culture of clean

– Get used to applying the above 4S

– Audit and Evaluate the standard

SORT (Organization)

Clearly distinguishneeded items from

unneeded items and eliminate

the latter

Keep needed itemsin the correct

place to allow foreasy & quick

retrieval

SET IN ORDER (Orderliness)

This is the condition we

support whenwe maintain the

first three pillars

STANDARDIZE (Standardized

Cleanup)

workshopswept and

clean

Keep the

SHINE (Cleanliness)

SUSTAIN (Discipline)

Make a habit of maintaining established procedures

Respect the rules we have imposed on ourselves:

by leaving no object outside the storage or unloading areas

by preserving delimited areas

by respecting indications

by cleaning the work area as per standard

Dangerous area

Get used to applying the 5S

Resistance to Implementing 5S

What are the reasons for resisting 5s implementation?

Resistance to Implementing 5S

What’s so great about sort and set in order? It will take too much time.

Why clean when it just gets dirty again?

Are sort, set in order, and shine really going to boost productivity?

Why bother?We already implemented sort and set in order.

We’re too busy for 5s.

We did 5s years ago.

What are the reasons for resisting 5s implementation?

Benefits of Implementing 5S

What are some benefits of implementing 5s?

Benefits of Implementing 5S

What are some benefits of implementing 5s?

Workers have an opportunity to provide creative ideas about how the workplace should be organized.

Higher job satisfaction.

Clear expectations.

Reduced delays mean timely delivery of product.

Reduced changeover time = higher productivity.

Elimination of cost causing waste.

Reduced defects and higher quality.

Safer environment.

Maintained machinery and equipment means reduced downtime.

Win customer confidence and trust.

Growth.

Implementing 5S

Implement SORT with a red tag campaign

Place red tags on items that need evaluation

Red-tagging is a method for identifying potentially unneeded items, evaluating their usefulness, and dealing with them appropriately.

Ask– Is this item needed?– If so, is it needed in this quantity?– If it is needed, does it need to be located here?

Implement SORT with a red tag campaign

Assign one area in plant / deptt for keeping unneeded material found from 1S activity

Keep the material in that area for predetermined period before discard them.

Discard the material if have no use.

Steps for Implementing the SET IN ORDER

Decide the location of items that eliminate waste– Principles of motion economy– 5S map

Tools– Signboards– Paint paths and areas– Color-coding– Outlining

Label locations– Area, specific placement, and amount

Once the best locations have been decided, you must identify locations so ANYONE will know:– What goes where

– How many of each item go in each location How?

– Outlining Strategy

– Signboard Strategy

– Painting Strategy

– “After” 5S Map

– Color-coding Strategy

Label Locations (SET IN ORDER)

Organize items so they are – easy to use – easy to find – easy to put away

Outlining Strategy (SET IN ORDER)

Sign Boards (SET IN ORDER)

Signboards have: Location

indicators

Amount indicators

Item indicators

Painting Strategy (SET IN ORDER)

Painting identifies locations on floors and walkways.

Place markers for work tables

Place markers for operators

Cart storage locations Pallet storage locations

Implement SHINE with careful planning

1. Determine targets (Identify all areas require cleaning)

Warehouse items (Storage Racks, Bins)

Equipments (Machines)

Space (Floor)

2. Determine assignments and schedule– Develop 5S Map of area/machine showing all equipments

and 5S Schedule for Sorting, Setting and Shining

3. Determine methods– Identify tools required for cleaning like brush, rag, air, vaccum

cleaner.– Develop the procedures for cleaning ie. How to clean

Implement SHINE with careful planning

4. Prepare cleaning tools

- Provide the Standardize storage for cleaning tools

- Inspect the cleaning tools regularly using Checklists

5. Shine

- Clean the machine, equipment, workarea by following the cleaning procedures.

Implementing STANDARDIZE

Decide who is responsible for which activities for maintaining 3S conditions

Integrate 3S maintenance into regular work duties

Check to see how well 3S conditions are being maintained

Establishing a method to maintain the first three pillars

Set up a schedule for cleaning (for workplace, office and beyond workplace)

Schedule should contain 4W+1H - What to clean - Where to clean - Whom to clean - When to clean - How to clean Schedule should be followed and checksheet filled daily

Implementing STANDARDIZE

Cleaning Schedule - Machine ______________

What Where Whom When How Remarks

Machine inside Fixture Operator Daily Using Brush

Machine outside On Top Operator Weekly Using Cloth

Machine Pipelines Upto 5 ft from m/c

Housekeeping

Weekly Using Cloth

Implementing STANDARDIZE

• Develop standard for practicing 5S daily

Implementing SUSTAIN

Make cleanliness a habit

Create conditions which will sustain your efforts

– Schedule time to maintain order and cleanliness

– Committed support and recognition from management –

– 5S Slogans– 5S Posters– 5S Maps– 5S Newsletters– 5S Tours– 5S Audits– 5S Storyboards

Implementing SUSTAIN

• Prepare Audit Checksheet

• Audit the Work Area daily • Audit should be done by CFT or Supervisor or Operator • Evaluate the audit findings

• Plan for correcting the problems

• Take approval for improvement

• Implement the improvement

• Sustain the improvements

Examples of 5S

5S of Shopfloor5S of Tools

5S of Desk

5S of Documents

5S of Beyond Workplace

5S of “5S Board”

5S of Tools

5S of Tools

Success with 5S

Before After

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Thank you!