Workplace Improvement With 5 S Rev3

Plakshi GyanTech The Knowledge Catalysts Workplace Improvements : 5-S Revision Number : 3.0 Revision Date : 01-Sep-2007 GT-0020-02 / 28-Jun-07

Copyright Notice This publication is protected by copyright law, with all right reserved. No part of this publication maybe reproduced, stored in a retrieval system translated, transcribed, or transmitted, in any form, or by any means manual, electronic, electro-magnetic, mechanical, chemical, optical or otherwise, without any means manual electronic electro-magnetic, mechanical, chemical, optical, or others wise, without prior explicit written permission from GyanTech Group We solicit your valuable feedbacks & suggestions for improvisation of this program, contents & logistics etc. Please feel free to provide us with your earnest and honest feedback . This will help us in improving our services and offerings. With Thanks. Plakshi GyanTech © 2007 service@gyantech.net 2

Ice Breaker (10 Minutes) Let’s speak out 1,2,3,4,5 in a sequence starting from my left hand side. The persons getting same number are in the same group. All group members to sit together and talk freely one minute or so. Now, you should introduce yourself, telling your name, location, profile, experience, basic objective in attending this program, expected achievements of this session and what specific things you wish to learn & implement at your workplace. Training Codec, Agenda, Time Limit & Breaks explanation. Plakshi GyanTech © 2007 service@gyantech.net 3

Introducing the Catalyst Vijay Kumar Saini is a practicing engineer in the Automobile Domain with rich exposure to the technology and management aspects. He is a Certified Quality Manager who has spent his 16 valuable years in search of excellence in Quality Realm. He has worked extensively as TQM expert, Quality Engineer, Kaizen Manager, Hoshin Kanri Expert during his professional career. Apart from designing a lot many thought provoking trainings, he has inscribed a few management & engineering related papers also. Plakshi GyanTech © 2007 service@gyantech.net 4

Training Codec Respect all Creature. You may criticize other’s idea logically & factually. Be a good Listener and a perfect Orator for the suitable situations. Please make notes of the discussion as record for your future references. while query, please mention slide no. and subject for clarity. Let’s stay together. Cross-talks are not allowed, unless instructed. Please Raise the point of common interest in public time. For specific issues, manage for private time. Your query shall be answered now or in near future. Please keep mobiles silent and avoid commotion during training. We can include additional breaks for convenience (If requested). The discussion shall be based on average level of intelligence. Also the training contents & examples may not suit every profile. So, please keep your minds open and ears alert for optimum learning, always. The explanation shall make all concepts & ideas clear in most generic way. All are ever learning. You are free to uphold your point of view. But arguments / contradiction in excess aren’t permitted due to time factor. Finally BEST OF LUCK for your learning with all of us around. Plakshi GyanTech © 2007 service@gyantech.net 5

Plakshi Workplace GyanTech Guru speaks about origin of 5-S Improvement According to Takashi Osada author of the Five 'S', Notes they have been there from a very long time. But we were not aware of them. If we look around the place, whether it is home or our work area we can always find lots of room for improvement. All the knowledge are never born nor these can be destroyed. A lucky few find it with conscious efforts. Plakshi GyanTech © 2007 service@gyantech.net 6

Plakshi Workplace GyanTech What are Five 'S' Improvement Five 'S' are derived from the first letters of the words Notes • SEIRI (Sorting or Clear-out) • SEITON (Straighten or Configure) • SEISO (Scrub or Clean & Check) • SEIKETSU (Systemization or Conformity) • SHITSUKE (Standardization or Custom) They are five integrated steps of housekeeping or workplace Management. You may remember any of Japanese or English 5 S or English 5 C name easily. Plakshi GyanTech © 2007 service@gyantech.net 7

Plakshi Workplace GyanTech What are Five 'S‘ literally Improvement Notes Japanese 5S English 5S English 5C Seiri Sorting Clear-out Seiton Straighten Configure Seiso Scrub Clean & check Seiketsu Systemization Conformity Shitsuke Standardization Custom There are many alternative translations of the Japanese 'S' words in English 'S' words! These S / C best convey the meaning and spirit. Plakshi GyanTech © 2007 service@gyantech.net 8

Plakshi Workplace GyanTech Offices are same as Factory Improvement FACTORY Notes Input Output Process ( RM ) (Tangible Product ) • Will have general affairs • Product generally sold to outside customers OFFICE Input Output Process ( Information ) (Information Service ) • Will have general affairs • Although information is produced, usually used in-house or in factory Plakshi GyanTech © 2007 service@gyantech.net 9

Plakshi Workplace GyanTech How to introduce 5-S Improvement Mr. Hiroyuki Hirano, an expert in 5-S suggests three step Notes method. • Step1: Tidy up first (active Five 'S') • Step2: Making of Five S a routine & habit. • Step3:Taking Five S to a higher level. (Preventive 5S) Details of Step 1 • Preparation : Recording the present situation • Process1: Eliminating unnecessary items • Process 2: Fixing Storage places • Process 3: Consolidating daily cleaning procedures • Process 4: Maintaining spotless workplace • Process 5: Visual control in the workplace Finally can you see the improvements? Plakshi GyanTech © 2007 service@gyantech.net 10

Plakshi Workplace GyanTech How to introduce 5-S Improvement Details of Step 2 Notes • Preparation : Photographing the new look at the workplace • Process 1: Controlling stock level • Process 2: Making it easy to use and return things • Process 3: Making clearing and checking habitual • Process 4: Maintaining spotless workplace • Process 5: Maintaining standards throughout the organization Finally has 5 'S' became a habit? Plakshi GyanTech © 2007 service@gyantech.net 11

Plakshi Workplace GyanTech How to introduce 5-S Improvement Details of Step 3 Notes • Preparation: Evaluating the factory where 5 'S' has become habitual • Process 1: Avoiding unnecessary items • Process 2: Avoiding disorganization • Process 3: Cleaning without getting dirty again and every time • Process 4: Prevents degradation of the Environment • Process 5: Systematization Training Finally has your factory become a first class 5-S factory? Plakshi GyanTech © 2007 service@gyantech.net 12

Plakshi Workplace GyanTech Benefits of 5-S Improvement Nice to work in a clean, beautiful, organized workplace. Notes Time taken to reach things minimized. Lesser time waste in information handling. Problems detected fast. Machine / production down-time reduced. Lower cost of production. More usable space. Better preventive maintenance. Higher employee involvement. Reduction in error / defects due to standardized procedures. Consistent and better quality product. Higher productivity. Lesser accidents. Higher employee morale. More time for improvement activities. Plakshi GyanTech © 2007 service@gyantech.net 13

Plakshi Workplace GyanTech Concepts followed in 5-S Improvement If there’s less no. of items there is less to clean. Notes • One is Best • One page memo • One day processing • One location files • One copy filing • One hour meeting • One minute phone call Reduce no of tools and gadgets • Reduce no. of bolt sizes • Use of winged nuts • Consolidate kinds of oil • Combine various tools & gadgets into one Plakshi GyanTech © 2007 service@gyantech.net 14

Plakshi Workplace GyanTech Concepts followed in 5-S Improvement Identify the famous seven wastes and eliminate Notes them from our workplace. • Storage • Transportation. • Over production. • Processing. • Motion of people / material. • Defects. • Waiting. Use 5W-2H tool to identify these wastes! Plakshi GyanTech © 2007 service@gyantech.net 15

Plakshi Workplace GyanTech Concepts followed in 5-S Improvement Notes Material Service Material Service Assembly Line Parts Inspection Parts Inspection Part Sub Assy. Assembly Line Part Sub Assy. Dispatch Final Quality Final Quality Dispatch Plakshi GyanTech © 2007 service@gyantech.net 16

Plakshi GyanTech The Knowledge Catalysts First S of the 5-S Seiri Sorting Clear-out GT-0020-02 / 28-Jun-07

Plakshi Workplace GyanTech First S : Sorting Improvement Segregating necessary from unnecessary and Notes throwing away what is not required at all & at any point of time. Determine what is needed and what is not needed. This is done with the objective of saving and recovering space. Tools, materials, parts, papers, stationery, filings, packaging materials etc. are all the targeted items of sorting out in office as well as factory premise. Plakshi GyanTech © 2007 service@gyantech.net 21

Plakshi Workplace GyanTech First S : Sorting Improvement Determine what is needed and what is not needed Notes Tools, materials, parts, packaging materials etc. If unsure, tag items for later evaluation. if unclaimed / or unwanted give them a 'dump by' date Plakshi GyanTech © 2007 service@gyantech.net 22

Plakshi Workplace GyanTech First S : Sorting Improvement When we have got rid of all the Notes clutter, we need to consider the best place for what is needed Prioritize the items and their respective usages Plakshi GyanTech © 2007 service@gyantech.net 23

Plakshi GyanTech The Knowledge Catalysts Second S of the 5-S Seiton Straighten Configure GT-0020-02 / 28-Jun-07

Plakshi Workplace GyanTech Second S : Straighten Improvement Place for everything and everything at it’s place. Notes A rational, orderly and methodical arrangement of all items we use, re-use, some times use, seldom use or write off. To Implement Straightening Arrangement • Analyze Status • Decide which things will belong where • Decide how they should be put on / away • Get everybody to follow rules thru Indexing, Labeling etc. Plakshi GyanTech © 2007 service@gyantech.net 27

Plakshi Workplace GyanTech Second S : Straighten Improvement Make it easy and approachable to keep things in Notes it's fixed place. Assign names, addresses, quantities, routes etc. for quick trace-ability. Plakshi GyanTech © 2007 service@gyantech.net 28

Plakshi GyanTech The Knowledge Catalysts Third S of the 5-S Seiso Scrub Clean & Check GT-0020-02 / 28-Jun-07

Plakshi Workplace GyanTech Third S : Scrub Improvement Understanding how to prevent things from getting Notes dirty and ensuring tip top clean condition. Cleaning the workplace to maintain the spic & span condition. Done with the objective of inspecting for problems and talking faster corrective actions. Clean workplace shows off the things not in order or having problem, easily. Plakshi GyanTech © 2007 service@gyantech.net 32

Plakshi Workplace GyanTech Third S : Scrub Improvement Cleaning enforces close scrutiny. Notes Simply inspecting and using a check sheet isn't good enough. All sorts of problems are encountered. We can start to understand some of the causes and start to put things right. Difficult to Loose access bolt Heavy soiling Plakshi GyanTech © 2007 service@gyantech.net 33

Plakshi Third S : Scrub Workplace GyanTech Improvement Bad examples Notes Broken gauges Damaged guards Clutter in electric box Worn couplings Oil leaks; loose hose couplings Plakshi GyanTech © 2007 service@gyantech.net 34

Plakshi GyanTech The Knowledge Catalysts Fourth S of the 5-S Seiketsu Systemization Conformity GT-0020-02 / 28-Jun-07

Plakshi Workplace GyanTech 4 S : Systemize Improvement We need to ensure people have all the means to maintain Notes first 3-S conditions. They need time & resources and willingness to carry out these activities on regular basis. There need to be System in place to ensure that people are trained in them, they adhere to them and these system are effective in achieving the desired results. Adherence can be charted or simply project pictures of actual vs. expectation at notice boards. Measuring effects of 5-S performance results demonstrate that the investment is worth it. Plakshi GyanTech © 2007 service@gyantech.net 37

Plakshi Workplace GyanTech 4 S : Systemize Improvement Having established tidier and cleaner equipment, facilities, and workplace, we Notes want to keep it that way! 'The norm' must be made obvious, and go beyond what things are and where they belong - we need to include aspects such as temperatures, place, pressure, settings and so on. Plakshi GyanTech © 2007 service@gyantech.net 38

Plakshi Workplace GyanTech 4 S : Systemize Improvement Checksheet helps to ensure Notes that normal condition can be recognized, and that it is monitored at regular intervals. Method standards ensure that checks are carried out in a pre- determined way which is safe, ensure quality of checking, and that they are carried out with the minimum time and effort. Plakshi GyanTech © 2007 service@gyantech.net 39

Plakshi GyanTech The Knowledge Catalysts Fifth S of the 5-S Shitsuke Standardization Custom GT-0020-02 / 28-Jun-07

Plakshi Workplace GyanTech Fifth S : Standardization Improvement Ensuring Conducive, lively and Safe Working Notes Environment. Making Cleanliness and prioritization a routine and a firm habit. Done with the objective of Achieving higher productivity and better quality through higher employee morale Follow all 4 –S with Self discipline. By the time clear standards are in place around the factory or office, and everyone is conforming to these, many of the problems that used to arise will be no more. The new challenge is to strive for even better Safety, Quality, Cost, Management and Delivery achievements whilst developing a workplace that is truly World Class. Plakshi GyanTech © 2007 service@gyantech.net 43

Plakshi Workplace GyanTech 5 S : Standardization Improvement The picture on the right is a Notes Japanese factory. The condition of the factory is very clean. When cleanliness of the workplace is well maintained, abnormalities are easily spotted and solved. Therefore, if work place is clean, processes will become more reliable to produce quality products. Only when level of cleanliness is high like in this kind of work place, producing ultra high quality products is possible. Plakshi GyanTech © 2007 service@gyantech.net 44

Plakshi GyanTech The Knowledge Catalysts Let’s Review All over again … GT-0020-02 / 28-Jun-07

Plakshi Workplace GyanTech Review Improvement Follow all of the 5-S religiously Notes Standardized work procedures. Maintain safe and hygienic conditions in workplace evolving serene atmosphere. Standardize and maintain • My job including product & processes. • My machine and equipments. • My work area and total workplace. Plakshi GyanTech © 2007 service@gyantech.net 48

Thank you very much for a patient listening, persuasive enthusiasm and earnest interaction ! Please refer your Comments / Queries / Questions at Vijay Kumar Saini service@gyantech.net +91 – 9810891691 We solicit your valuable feedbacks & suggestions for improvisation of this program, contents & logistics etc. Please feel free to provide us with your earnest and honest feedback . This will help us in improving our services and offerings. With Thanks. GT-0020-02 / 28-Jun-07

Revision Record & Acknowledgment Rev Revision Date Reason of Revision 0.0 01 July 1999 First preparation 1.0 01 Mar 2003 Included few latest photographs 2.0 01 Sep 2006 Format Changed 3.0 01 Sep 2007 Content Improvisation THANKS FOR THE VALUABLE CONTRIBUTIONS : GOD Almighty – Who gave me the ability and opportunity to contribute the amateur thoughts in His vast ocean of knowledge. I owe you everything I know, have and create. My Family - Who cultivated and honed my skills from the scratch and keeps on encouraging me for winning new horizons. My work is a result of their dedication and relentless support. Thanks for everything Plakshi GyanTech © 2007 service@gyantech.net 50

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Workplace Improvement With 5 S Rev3

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