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5 S Program Orientation Powerpoint Presentation

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5S

5S

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  • 1. 5S PROGRAM Module Training
  • 2. COURSE CONTENT Day 1 • INTRODUCTION • WHAT IS 5S? • 5S IMPLEMENTATION Day 2 • WHAT CAN YOU GAIN FROM 5S? • WHY 5S BRINGS SUCH BENEFITS? Day 3 • HOW TO MOTIVATE PEOPLE TO PRACTICE 5S? • DESIRABLE CULTURAL CHANGES AFTER 5S. Day 4 - Workshop • GROUP PRESENTATION
  • 3. INTRODUCTION • 5S & PRODUCTIVITY – To improve productivity Ultimate Goal Better tomorrow for everyone Effective use of resources Intermediate Goal Efficiency improvement Economic Operation Approach Strategy Method JIT / TPM / TQC / ISO / 6-Sigma  WORK QUALITY  “The way in which you treat the work environment is the way you treat your customer.”
  • 4. WHAT IS 5S? S...? S…? S…? S…? S…?
  • 5. WHAT IS 5S? • 5S Concepts Japanese English SEIRI SORT SEITON SYSTEMATIZE / STANDARDIZED SEISO SWEEP SEIKETSU SANITIZE SHITSUKE SELF-DISCIPLINE 5S is not simply a list of Action Items. It is an integrated concept of actions, condition and culture.
  • 6. WHAT IS 5S? • SORT is an ACTION to identify and eliminate all unnecessary items from your workplace. • SYSTEMATIZE is an ACTION to put every necessary items in good order. • SWEEP is an ACTION to clean your workplace thoroughly. • SANITIZE is a CONDITION where high standard of good housekeeping is maintained so that there is no dust and rust anywhere. • SELF-DISCIPLINE is a CONDITION where all members practice the above 4S’s spontaneously and willing as a way of life. Accordingly, it is a CULTURE.
  • 7. How to practice 5S? • SORT – “TAKE OUT UNNECESSARY ITEMS”. NEVER KEEP ANYTHING WHICH ARE UNNECESSARY TO YOUR WORK.
  • 8. Some typical areas where SORT might be applied • Separate needed items from unneeded items. • Remove unneeded items from working areas. • Items never used: discard. • Item not needed now: store them. • Remove all excess items from working areas, including work pieces, supplies, personal items, tools, instruments, and equipment). • Use red tag to get rid of unneeded items. • Store items needed by most people in a common storage area. • Assign a person to organize and manage the common storage area. • Store items only needed by each individual in his/her own working area. • Organize working / storage area
  • 9. How to practice 5S? • SYSTEMATIZE – “ARRANGE NECESSARY ITEMS IN GOOD ORDER FOR USE”. LABELING
  • 10. SYSTEMATIZE – Objectives and Guidelines • Objectives: – Needed items can be easily found, stored and retrieved. – First-in first-out (FIFO). – Save space and time. • Guidelines: – A place for everything and everything in its place. – Place tools and instructional manual close to the point of use. – Design the storage areas such that the entrance is wider and the depth is shallower. – Layout the storage area along the wall to save space. – Place items such that they are facing toward passage for easily access. – Store similar items together. Different items in separate rows. – Don't stack items together. Use rack or shelf if possible. – Use small bins to organize small items. – Use color for quickly identifying items. – Clearly label each item and its storage areas (lead to visibility). – Use see-through cover or door for visibility. – Use special designed cart to organize tools, jigs, measuring devices, etc., that are needed for each particular machine.
  • 11. How to practice 5S? • SWEEP – “CLEAN YOUR WORKPLACE”. 3 MINUTES DAILY CLEANING WEEKLY 5S TIME
  • 12. SWEEP – Objectives and Guidelines • Objectives: – Cleanliness ensures a more comfortable and safe working place. – Cleanliness will lead to visibility so as to reduce search time. – Cleanliness ensures a higher quality of work and products. • Guidelines: – Use dust collecting covers or devices to prevent possible dirt or reduce the amount of dirt. – Investigating the causes of dirtiness and implement a plan to eliminate the sources of dirt. – Cover around cords, legs of machines and tables such that dirt can be easily and quickly removed. – Operators clean their own equipment and working area and perform basic preventive maintenance. – Keep everything clean for a constant state of readiness.
  • 13. How to practice 5S? • SANITIZE – “MAINTAIN HIGH STANDARD OF HOUSEKEEPING”. COMPETITION AUDIT
  • 14. SANITIZE - Things that workers have done under the heading of standardized clean-up • Removing used, broken, or surplus items from the work area • Making safety a prime requirement by paying attention to noise, fumes, lighting, cables, spills, and other aspects of the workplace environment • Checking that items are where they should be • Listening to the "voice" of the process and being alert to things such as unusual noises • Ensuring that there is a place for everything and that everything is in its place • Wearing safe working apparel and using safe equipment • Minimizing all waste and the use of valuable resources such as oil, air, steam, water, and electricity
  • 15. How to practice 5S? • SELF-DISCIPLINE – “DO THINGS SPONTANEOUSLY WITHOUT BEING TOLD OR ORDERED”.
  • 16. SELF-DISCIPLINE • The last step of "5S", Shitsuke, means 'Discipline.' Discipline means doing things the way they are supposed to be done. The emphasis is on creating good work habits. By teaching everyone what needs to be done and having everyone practice it, bad habits can be broken and good ones formed. • Shitsuke denotes commitment to maintain orderliness and to practice the first 4 S as a way of life. The emphasis of shitsuke is elimination of bad habits and constant practice of good ones. Once true shitsuke is achieved, personnel voluntarily observe cleanliness and orderliness at all times, without having to be reminded by management. • Self-discipline is important because it reaches beyond what management can impose. If a worker does something only because he or she has been required to do it by a manager, there is a good chance that the worker may have to be reminded again (and again) to do the same thing). (Think of your mother demanding that you keep your room clean when you were a teenager). By contrast, self-discipline more or less guarantees the continuity of a daily routine. Self-discipline basically says "follow procedures in the workplace".
  • 17. Office 5S • KEY AREAS FOR OFFICE 5S 1. Physical and Psychological Aspect 1. Communication 2. Material and machine handling (document, equipment, stationery) 3. Movement of personnel 4. Good impression for customer and worker 2. Organization Aspect 1. Effectiveness of organization units based on input/output. 2. Restructuring of organization by means of combinations, elimination, etc. 3. Vitalizing organizational units especially for cross-functional activities 3. Information Processing Aspect 1. Upgrading quality, response time, cost effectiveness 2. Efficient O/A system 3. Upgrading productivity consciousness and working skills
  • 18. Office 5S Activities 1. Reducing the number of ledgers, forms, tools. 2. Better storage to get anything needed in 30 seconds. 3. Keep things in just one place. 4. Have just one form for things. 5. Eliminate the idea that everyone has to have his own copy of everything. 6. Shift from individual-based to group based work. 7. Standardize and create manual detailing office procedures. 8. Provide mechanism to evaluate what is happening at anytime. 9. Maintain cleanliness and orderliness.
  • 19. ONE is Best-Campaign • One location • One-day processing • One-file projects • One-hour meetings • One-page memos • One-copy filing • One-minute telephone calls • One-too work
  • 20. 5S IMPLEMENTATION Step 1 Step 2 Step 3 Step 4 Step 6 Step 5 Establish 5S Develop Specific Develop Communication Develop 5S Training Implement 5S Implementation Team Verification of Effectiveness Implementation Plan Plan Plan
  • 21. 5S IMPLEMENTATION • KEY POINTS IN THE IMPLEMENTATION OF 5S 1. Start small and easy, proceed slowly but steadily. 2. Start with the most suitable “S”. 3. Only 1 or 2 or 3S’s are enough for the initial practice not all 5S’s. 4. Set simple easily achievable and step-by-step targets. 5. Everyone’s participation is important 6. Management should take leadership of 5S movement 7. Record improvements for comparison 8. Devices schemes to stimulate awareness and sustain enthusiasm 1. Promotional Schemes – banners, slogans, posters, newsletter, competition, badges 2. Implementation Schemes – 5S day, spot shooting, big clean-up day, 3-minute cleaning 3. Evaluation Schemes – 5S evaluation sheet, audit, periodic review
  • 22. 5S IMPLEMENTATION • STEPS TO BE FOLLOWED IN THE IMPLEMENTATION 1. General Situation Appraisal 1. Picture taking/video 2. Benchmarks/standards 2. Management Orientation 3. Formation/Organization of 5S Committee 1. Education program 2. Promotion plan 3. Initial Practices 4. Evaluate 4. Initial Practice 1. Launching 5. 5S Evaluation 1. Fixed point photography 2. Walking Rally by top and middle management 3. Competition among departments/workplaces 4. Combination of the ABOVE
  • 23. 5S IMPLEMENTATION • FACTORS LEADING TO SUCCESS OF 5S 1. Strong sponsorship and leadership of CEO 2. Active promoter/5S committee 3. Good launching activity 4. Regular audits 5. Good documentation 6. Competition
  • 24. 5S IMPLEMENTATION • FACTORS WHICH HINDER SUCCESS OF 5S 1. Project sponsor is not the decision maker 2. Organizational politics 3. Lack of experience in undertaking cross- functional activities 4. Lack of top management support 5. Implementation carried out through orders from top 6. Implementation done by task forces 7. 5S treated as a project 8. Emphasis on immediate results
  • 25. DAY 2 – 5S Program Orientation • Recap • WHAT CAN YOU GAIN FROM 5S? • WHY 5S BRINGS SUCH BENEFITS?
  • 26. RECAP - What is 5S? • SORT – is an ACTION to identify and eliminate all unnecessary items from your workplace. • SYSTEMATIZE – is an ACTION to put every necessary items in good order. • SWEEP – is an ACTION to clean your workplace thoroughly. • SANITIZE – is a CONDITION where high standard of good housekeeping is maintained so that there is no dust and rust anywhere. • SELF-DISCIPLINE – is a CONDITION where all members practice the above 4S’s spontaneously and willing as a way of life. Accordingly, it is a CULTURE.
  • 27. WHAT CAN YOU GAIN FROM 5S? What can an INDIVIDUAL gain from 5S? 5S makes your workplace more pleasant Improved human relations and working environment will make your workplace more pleasant. 5S makes your work more efficient wasting time = wasting energy and moral
  • 28. WHAT CAN YOU GAIN FROM 5S? What can an INDIVIDUAL gain from 5S? 5S improves your safety A clean and tide working environment where everything is properly placed, clear instructions are readily available and no one throws anything is a safer place to work in. 5S improves QUALITY of your work and your output People affect environment = Environment affects people Good environment will improve quality of your work. It is quite natural that quality products comes only from clean and well organized workplaces.
  • 29. WHAT CAN YOU GAIN FROM 5S?  What can the COMPANY gain from 5S? P.Q.C.D.S.M. P - Improved Product/ Customer Satisfaction Service Options Q - Improved Quality C - Reduced Costs D - Consistent Deliveries S - Improved Safety M - Improved Morale SELF-DISCIPLINE Factors to productivity improvement
  • 30. SORT (and separate out) “Take out unnecessary items” Unneeded/outdated items Scattered things in the are on walls area. Unnecessary items in the area Gain: Improvement: Creation of extra work space Quality improves Work flow becomes more visible Safety improvements It is a better place to work Productivity improves
  • 31. SYSTEMATIZE (or simplify) “Arrange necessary items in good order for use”. Gain: 1. Makes the worker's job easier and safer 2. Identify problems more quickly 3. Reduced inventory and supply - Less waste in materials 4. Less waste of motion (tools and supplies are located where needed at point of use) Improvement: Filing - Storage  Improved Productivity  Safety is improved with organized work places
  • 32. SWEEP (or scrub) “Clean your workplace”. Tangles / loose cables Unsafe condition Gain: Improvement: Less risk Quality improvement Cleaner and more satisfying place to Safer place to work (fewer accidents) work
  • 33. SANITIZE (or standardize) “Maintain high standard of housekeeping”. 1. Daily or weekly 5S Gain: 2. Spread the ideas to other Improves QUALITY of your work and your output areas - Training, Posters, Positive change – role model Visual Aids Improvement: Productivity improvement Promote stronger communication among staff Empower employees to sustain their work area
  • 34. SELF-DISCIPLINE (or sustain through self-discipline) “Do things spontaneously without being told or ordered”. 1. Report unsafe Gain: condition, defective 1. Good perception – role model machine/equipments 2. Minimize waiting time, Reduced machine down 2. Follow-up on actions time and responsibilities 3. Maintain 5S program (feedback, regular Improvement: audits) 1. Improved Morale 2. Improved Quality and Productivity
  • 35. WHY 5S BRINGS SUCH BENEFITS The process of 5S requires people to think, consult and agree with others, and cooperate with each other. At the same time, practicing 5S gives people satisfaction of being creative, friendly with others and seeing changes for better. In summary, 5S improves.. HUMAN CAMARADERIE/ TEAMWORK COMMUNICATION CREATIVITY RELATIONS COMRADESHIP VITALITY
  • 36. DAY 3 – 5S Program Orientation • Recap • HOW TO MOTIVATE PEOPLE TO PRACTICE 5S? • DESIRABLE CULTURAL CHANGES AFTER 5S. • CONCLUSION
  • 37. HOW TO MOTIVATE PEOPLE TO PRACTICE 5S? • PERIODIC 5S AUDITS – Establish 5S evaluation and incentive plan – Conduct 5S evaluation inspection regularly • INTERDEPARTMENTAL COMPETITION – Organize continuous interdepartmental 5S competition – Periodically award groups and individuals
  • 38. PLANNING FOR IMPLEMENTATION  Organize the program committee. (PLAN)  Develop a plan for each S . (PLAN)  Publicly announcement the start of the program. (DO)  Provide training and education to employees. (DO)  Select a day and everybody cleanups his/her own working area. (DO)  Select a day and everybody organizes his/her own workplace. (DO)  Evaluate the results of 5S. (CHECK)  Self-examination and Take corrected actions. (ACTION)
  • 39. SUSTAINING 5S 1. Key # 1 : Commitment 2. Key # 2 : Top Management Support 3. Key # 3 : Performance Measurement & Reward System
  • 40. Fixed Point Photography Method • Step 1 – You designate points and directions where photographs are going to be taken continuously. • Step 2 – Before you start 5S, you take photographs and show to the people concerned. • Step 3 – After the first action on 5S, take photographs again and show these to the people again. • Step 4 – Keep taking photographs regularly and show to the people. BEFORE AFTER
  • 41. WHY 5’S ? 1. Controls the work conditions rather than the worker’s behavior 2. Is relatively inexpensive for the company to implement 3. Makes the worker’s job easier and safer 4. Promotes daily activity for continuous improvement 5. Fosters efficiency and productivity while improving work flow 6. Encourages a proactive approach that prevents problems and waste before they occur 7. Provides a practical method for dealing with the real problems that workers face everyday 8. Fits with a company’s other efforts, such as pollution prevention, safety initiatives, and lean manufacturing
  • 42. 5’S CONCLUSION REFORM CHANGE BASICS