5S and quality Auditing Project

1. Quality Project
BSL 5S

2. Quality Project Detail
Project Name BSL 5S Section:
Project Open Date 25/03/2016
Project Complete Date
Project Category 5s Implementation
Project Team
Name Qualification Phone no Email ID
Anmol Singh Mangat B.Tech (Mechanical) 9888033499 Eranmol@live.in
Arshdeep Singh B.Tech (Mechanical) 9888650600 arsh9400@gmail
.com
Review Committee
Shop Floor Management
Anuj Saxena Mr.Rajpal
Sharma
Major Singh

3. What is 5 S ?
Finding a place for
everything and putting
everything in its place.
5s is a systematized
approach to organized
work place, keep rule,
standards & maintain the
discipline needed to do a
good job in Organization.
3

4. 4
5S Concept
In 1980,Japanese realized to get the right
production & Quality, a system was required.
So the concept 5S was formulated.

5. Objectives
1.Improve housekeeping.
2.Make every one responsible for housekeeping.
3.Make Productivity improvement, saving time
and Increase space etc.
5

6. 1. To eliminate the wastes that result from uncontrolled
processes.
2. To gain control on equipment, & material inventory.
3. Apply Control Techniques to Eliminate Erosion of
Improvements.
4. For maintenance of critical Process Parameters.
6

7. 7
1-Sorting
2-Systematic Arrangement
3-Shine
4-Standardization
5-Sustain
It is a Japanese Word, whose meaning, Sorting,
Systematic arrangement, Shine, Standardization , Self
Discipline. All words begin from English Letter “S”
& In all 5 words, First word is “S”.
Name of 5S

8. Implementation of 5S
In industry

9. The word Sorting
means, segregate the
necessary &
unnecessary items.
Keep the necessary
items in work place &
red tag the
unnecessary items.
9
1-SORTING

10. Sorting
10
Red Tag Activity ¼
5S RED TAG
Section:
Name of Item: Quantity:
Reason:
Action:
Target Date:
Remark:
1. Move to scrap yard.
2. Locate properly.
3. Segregate
4. Rectify
5. Return to supplier
6. Others
1. Obsolete.
2. Defective.
3. Scrap
4. Not in Location
5. Unnecessary
6. Mix up
7. Unidentified
8. Others
vizPkk
fyr
Sorting: Identify,
Segregate the wanted &
unwanted things.
Out:-Remove unwanted
things.

11. Not
Necessary
Not
Necessary
Stage-1 Stage-2 Stage-3
Do not leave Sorting half done. All of the unnecessary items should be discarded.
Sorting
11

12. As your Choice, In Work Place or Home, First See the all things then
sorting which are necessary things and Unnecessary things. It will be
done timely.
Sorting
12

13. Sorting
Condition After -S1
13
AFTERBEFORE
Unwanted Items

14. Condition After -S1
Sorting

15. Keep the daily requirement things nearer and other things can be kept
at a distance or in a defined store room.
Sorting
15

16. A Simple Flow chart
Sorting
Item
UselessUseful
Keep & Monitor
UnknownUseful
Sorting
Keep in store
Dispose
Useless
16
Storage

17. Implementation of S1
1. Implemented the S1.
2. Then check the S1 status.
3. If ok then go to S2
4. If not ok then again do S1.
OK Not OK
S1
S2
17

18. Place necessary
items at proper
position for
practical usages &
clearly indicate
the contents so
that everyone can
understand.
18
2-Systematic Arrangement

19. Systematic Arrangement
The habit of
systematic
arrangement
indicates, a place for
every thing and
every thing in its
place.
19

20. Why is time wasted looking for something?
Because Storage is not designated.
Let me know
my place!
20
Systematic Arrangement

21. Tools organizer helps to
organize the small
tools. It can eliminate
the need of searching
for tools when needed.
It can also prevent
tools from wearing out
and rusting.
Example of Systematic Arrangement and
Visual Control
Use Tools Organizer to Organize Tools.
21
Systematic Arrangement

22. Space Should be compressed so that It can not move anywhere.
Defined place for stand. Space marked for stand.
Fixed Location of Stand
22
Systematic Arrangement

23. Labeling done for visual Control.
(using relative colors.)
Marked location labeled with names of the items.
Location marked for different materials.Different items found scattered on the board.
Location of Various Material on White Board
23
Systematic
Arrangement

24. 5S Implementation - Examples
24
BEFORE AFTER
BEFORE AFTER
Systematic
Arrangement

25. Tools are organized as set-in-order.Tools are not arranged properly.
25
Tool Board
Hammer
Spanners
Screw Drivers
Adjustable
Spanner
Systematic Arrangement
BEFORE AFTER
Pliers
Wire cutters

26. BEFORE
26
Files are arranged systematically.
1. Accounts file
2. RGP FILE
3. Invoice file
4. Attendance File
5. Blank format file etc
.
.
List of contents
AFTER
2
3
4
5
6
7 8
9 10
1
Systematic Arrangement

27. Keep the heavy things in the down
rack and light things in the upper
Rack.
27
First keep the big box on shop Floor
then small box above it.
Systematic Arrangement

28. In Almira, Systematically
arrange the things according
to the use.
(shape, size & weight)
28
For Caution, Use the boards,
messages, directions etc. as any
body can read easily and take
action on it.
Systematic Arrangement

29. Use
Helmet
DispensaryFire Hose Fire
Extinguisher
Electricity
ATTENTION
240/440 V
DANGER
No Smoking FireDon‘ Touch Danger
Vehicle
Visual Aids
29
Systematic Arrangement

30. 1. Implemented the S2.
2. Then check the S2 status.
3. If ok then go to S3.
4. If not ok then again do S2.
OK Not OK
S2
S3
Implementation of S2
30
Systematic Arrangement

31. The meaning of
SHINE is
cleaning,means
cleaning every
Place. Cleaning
process always to
shine the work
place & around it.
31
3-SHINE

32. Shine
Teach the present cleaning
system to everyone as he
feels, How cleaning is
done systematically.
32
Cleaning is to create the
working area where special
cleaning become
unnecessary through daily
check & measure for cause
of dirt.

33. 1. Cleaning should be done
regularly.
2. Use the best cleaning
agent.
3. All the corners should be
cleaned.
4. Keep all the labels intact.
5. All the labels should be
correct & visible to all.
Shine
33

34. Shine

35. Cleaning Results
BEFORE AFTER
Appropriate paint selection will help avoiding frequent rusting problem.
Shine
35

36. Shine
Teach the cleaning responsibility to all.
36

37. Cleaning the Machine Cleaning the work area
Shine
37
• Under Shine, Keep cleaning up the working area & shop floor.
• Making tools, floors, machines and instruments CLEAN.

38. Shine
38
Cleaning the scrap around the machine area. Not only must be clean his
working area but also the surrounding.

39. Benefits
of
Practicing ‘CLEANINIG’
1. Provides dust free environment.
2. Creates safe & healthy work place.
3. Ensures higher quality work
4. Increases the efficiency of work & life of
equipment .
5. Improves Visibility to identify abnormalities.
Shine
39

40. OK Not OK
S3
S4
Implementation of S3
40
1. Implemented the S3.
2. Then check the S3
status.
3. If ok then go to S4.
4. If not ok then again
do S3.
Shine

41. Sorting, systematic
Arrangement & shine are
done easily but maintaining it is difficult. For this, standardize the work.
The aim, is to make a standard procedure to follow sorting,
systematic arrangement & cleaning on daily routine.
Aim
41
4-STANDARDIZATION

42. 1. Regularizing 5S activities by putting systems in
every place so everyone does things the same way.
2. Make it easy for everyone to identify the state of
normal or abnormal condition.
3. For maintaining previous 3S, use visual
management.
Standardization
42
Activity

43. 43
 Colour coding.
 Use of Labels.
 Danger alerts.
Directional arrows/ marks.
Transparent covers.
Temperature labels.
Responsibility labels.
Some methods for visual communication
321
43
Standardization

44.  Traffic signal.
 Zebra crossing.
 In car
* Petrol indicator.
* Speed indicator
 Direction of arrows.
 Electric danger sign etc.
Some everyday visual management examples
654
44
Standardization

45. File Storage Rack
45
Standardization

46. Record Room
Inventory , Information & Process Control thru.
visuals
Canteen
46
Standardization
Low
Level
High
LevelEmergency
Exit

47. Standardization
Oil-24 Oil-32 Oil-68 Oil-90
47
Centralized Oil Storage SYSTEM
Not in use

48. Keep the floor dry,
either you can fall.
फर्श सूखी रखें
अथवा आप गिर
सकते हैA
48
Standardization
Message must be clear as it reads from far distance & also
apply Special colour in it.

49. Imagine friend, if you are not wearing helmet then…?
49
Standardization

50. OK Not OK
S4
S5
Implementation of S4
50
1. Implemented the S4.
2. Then check the S4 status.
3. If ok then go to S5.
4. If not ok then again do S4.
Standardization

51. Sustain means,
Acquire the habit
of doing what has
been determined
according to the
set rule.
51
5-SUSTAIN
(Self Discipline)

52. 52
Objectives
To bring a cultural change in the
organization.
…… Achieve
through………
“Total Employee Involvement”
Self Discipline

53. 1. Eat & smoke at designated area.
2. Keep work place always clean & tidy.
3. Wear clean uniform & shoes.
4. Follow safety rules.
5. Put things back in their proper place
after use.
6. Work according to the standard.
Self Discipline Practice
53
Self Discipline

54. Self Discipline
Are you judging with almira ?
54

55. Self Discipline
Now, there is no chance any
type of Fault in it.
After finish of work, Should
not forget to keep all the
things in their respective
place as easy to find in next
day.
55

56. 1. Implemented the S5.
2. Then check the S5 status.
3. If ok then Achieve the 5s level.
4. If not ok then again do the S1 to S5 cycle wise.
OK
Continue
Not OK
Restart 5S activity
from the start S1,
S2,S3,S4→S5
S5
Starts Periodically,
1.Weekly
2. Monthly etc.
Check
the
result
Implementation of S5
56

57. 5s Cycle
S5
S4
S1
S3
S2
Do the S4
. If ok then go to S5
. If not ok then again go to S4.
Do the S3.
. If ok then go to S4.
. If not ok then again go to S3.
Do the S2.
. If ok then go to S3.
. If not ok then again go to S2.
Do the S1.
. If ok then go to S2 .
. If not ok then again go to S1.
Do the S5
. If ok then continue.
. If not ok then again go to S1.
57

58. Dividing Company
Into different zones

59. 5S Zone Leaders
Zone Zone Leader
Zone No-1 Mr.Saurabh Dhawan
Zone No-2 Mr.J.S.Thakur
Zone No-3 Mr.Harpal Singh
Zone No-4 Mr.Ved Parkash
Zone No-5 Mr.Jora Singh
Zone No-6 Mr.Ram Sahaye
Zone No-7 Mr.Jasbir
Zone No-8 Mr.Sukhdev Singh Bhatia

60. 5S Zone No-1
Location:- Adminstrative Block 1st flor/pantary
/reception / main store
Post Name
Zone Leader Saurabh Dhawan
Subzone Leader
Members

61. 5S Zone No-2
Location:- Time office /main gate /security /diesel
storage tank /main passage to car parking/
weighing scale /car parking/scrab room
Post Name
Zone Leader J.S.Thakur
Subzone Leader Parveen Kr.
Members Shiv Kumar
Manoj Kumar
Krishan Kr.
Vijay Mishra

62. 5S Zone No-3
Location:- C-92 ground floor / paint shop/ manual
phosphatins / pipe store
Post Name
Zone Leader Harpal Singh
Subzone Leader
Members

63. 5S Zone No-4
Location:- Tool room / fabrication area/ utilities /
hall group no:10 & adjoining hall
Post Name
Zone Leader Ved Parkash
Subzone Leader
Members

64. 5S Zone No-5
Location:- C-85 basement workshop/raw material
store / final inspection / forge shop
Post Name
Zone Leader Jora Singh
Subzone Leader
Members

65. 5S Zone No-6
Location:- Incoming Section/ raw material
Post Name
Zone Leader Ram Sahaye
Subzone Leader
Members

66. 5S Zone No-7
Location:- C-93 work shop / pipe section /HMCL
under bracket line /VMC section
Post Name
Zone Leader Jasbir Singh
Subzone Leader
Members

67. 5S Zone No-8
Location:- C-94 work shop/ final inspection area /
job off loading area / sheet storage area
Post Name
Zone Leader Sukhdev Singh Bhatia
Subzone Leader
Members

68. Audit
Scheduling

69. Week wise Schedule
ZONE WEEK 1 WEEK 2 WEEK 3 WEEK 4
Zone No.1 Tuesday
Zone No.2 Thursday
Zone No.3 Tuesday
Zone No.4 Thursday
Zone No.5 Tuesday
Zone No.6 Thursday
Zone No.7 Tuesday
Zone No.8 Thursday

70. Audit Preformed On Date
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1
2
3
4
5
6
7
8
Zones Dates