Housekeeping - 5 step Programme

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As part of the Lean Toolbox, the most useful starting point is (often) 5S.

Of course modern versions talk of "6S". - personally I don't as Safety goes without saying!

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Housekeeping - 5 step Programme

  1. 1. Housekeeping (aka 5S)
  2. 2. Housekeeping (aka 5S) SEIRI SEITON SHITSUKE SEISO SEIKETSUSort Set Shine Standardise Sustain
  3. 3.  Clear Out  Configure  Clean and Check  Conformity  Custom and Practice Housekeeping (aka 5C)
  4. 4. Housekeeping: Overview  The importance of Housekeeping  How (poor) housekeeping affects our work  How we can all help to keep our workplace clean and organised  Objectives:
  5. 5. Housekeeping  A clean, organised workplace: Has higher productivity Has fewer defects Has fewer accidents Our customers expect it!  Why?
  6. 6. What 5S isn’t  A tidy up before the boss comes in showing a major new customer (or the CEO) around!  Just about tidying up other people’s rubbish  A quick sweep of the floor and placing tools back in the toolbox (until it all goes quiet again)
  7. 7. Consequences of poor housekeeping Amount of defective product Number of machine breakdowns Material flow (excessive travel) Inventory level Lost time in looking for materials Concealed problems Accidents/Incidents/Near misses
  8. 8. Housekeeping (5 steps) Remove Arrange Clean Maintain Train  Clear Out (Sort)  Configure (Set)  Clean and Check (Shine)  Conformity (Standardise)  Custom and Practice (Sustain)
  9. 9. Step 1-Sort  Take out unnecessary items & throw them away  Look around for things belonging to you which are not used anymore  Use disposal notices for things in your area which belong to others but appear not to be used  Check the disposal notices and act accordingly
  10. 10. Step 1-Sort Example: DISPOSAL NOTICE Inspector's Name Description of Item Date Posted Reply by Date Record no.
  11. 11. Step 1-Sort  Red Tagging  Red tag teams tag EVERYTHING which in their judgement is not needed at given workstation  Red tags have 3 classifications: Needed Un-needed Useless Note: Un-needed has further categories
  12. 12. Step 1-Sort  Red Tagging (cont.)  Needed: Required within 30 days (not arranged properly)  Un-needed A:  Not used in last 30 days, no planned use in next 30 days- change location (but keep accessible!)  Un-needed B: Not in use currently, required in the future >6 months-clean/organise/relocate/return (sell)  Un-needed C:  Not used in last 6 months, no planned used in next 6 months-relocate/return/sell.  Useless: No longer required, sell/return/discard
  13. 13. Step 1-Sort  Red Tag Review:  Record usage of anything in the area.  TAKE ACTION ACCORDING TO RESULTS
  14. 14. Step 2-Set  Arrange all NECESSARY items in a proper order  Look at the way things are arranged, remember EVERYTHING should have a proper accurate & RECORDED location  Take the frequency of use into account  Keep track of things by using lists or labels for cupboards or drawers, use shadow boards for Tools
  15. 15. Step 2-Set  After that:  Implement painting/marking strategy:  Clear markings:  Traffic, hazards, storage, flow, usage  Colour Coding:  Waste disposal,  Product/raw material segregation
  16. 16. Step 3-Shine  Clean your working environment until there is NO dust or dirt anywhere Clean environments enable you to see problems more clearly
  17. 17. Step 3-Shine Be conscious of maintaining a clean environment Create a maintenance system for housekeeping Hold inter-departmental competitions on housekeeping  Maintain a high standard of housekeeping at all times:
  18. 18. Step 3-Shine  Don’t wait for things to get dirty before you clean them  Put aside 5 minutes EVERY day to clean your workplace  Be responsible (with your colleagues) for the area around your workstation  Don’t create mess, you’ll only have to clean it up!  TIPS:
  19. 19. Step 4-Standardise  Maintaining the standard gives everyone a sense of involvement and pride in the job.  HOW? Hold inter-department inspections on housekeeping Review the results of these inspections and appoint HOUSEKEEPING CHAMPIONS
  20. 20. Step 5-Sustain  Training helps people to follow good housekeeping independently  HOW?  Always remember the value of your own housekeeping  Treat your workplace as your second home  Be aware of your own attitudes & habits  Don’t put up with bad housekeeping in other areas
  21. 21. Step 5-Sustain  3rd class workplace: ‘In my workplace everyone leaves things lying around and nobody clears up.’ 2nd class workplace: ‘In my workplace people throw things around but there are cleaners who tidy the place up.’ 1st class workplace: ‘In my workplace, nobody throws things around and everyone helps to keep the place clean.’
  22. 22. Housekeeping What do we gain from 5S? √ 5S makes the workplace more pleasant √ 5S makes work more efficient √ 5S and safety go hand in hand √ 5S helps deliver better quality products and higher productivity
  23. 23. 4-Steps to organising your workplace  Separate things which are necessary EVERY day from those which are not  Use red-tag/disposal notices to identify each item  Find a place for everything and put everything in that place  Always keep up the discipline of good housekeeping
  24. 24. Your observations  As a group visit your area(s) and look for the following:  2-3 Examples of GOOD Housekeeping  2-3 Examples of BAD Housekeeping  For each example:  Take photo(s)  Record WHY the example is good or bad
  25. 25. Discuss each example:  Group into good or bad practice  Place the pictures somewhere visible  Record details next to the picture  Discuss recommendations for improvement Be prepared to feedback your findings to everyone in your area Actions
  26. 26. 5S rollout – timetable Action: Notes: 5S presentation TODAY! Work through area look for items which don't belong 2-3 people per area then swap Red Tag items – move to ‘Crimewatch Corner ' Keep accurate list and publish to everyone RED TAG IN PLACE FOR NO MORE THAN 1 MONTH!! Re-organise Materials based on 5S Look at frequency of use and develop layout to suit Review Look at successes and failures – see what works & what doesn’t - rework as necessary Look at initial 5S audit to measure progress Start audits – check audit sheet is ok

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