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5S
THE SECRET TO
JAPANESE
SUCCESSPresentation by : GAURAV KUMAR (FDI)
WHAT PROBLEMS DO U COMMONLY
ENCOUNTER AT YOUR WORKPLACE
HIGH ABSENTEEISM
HIGH TURNOVER
DEMOTIVATED EMPLOYEES
DISORDERED/ CLUTTERED ENVIRONMENT
MISTAKES/ERRORS
THE SOLUTION TO ALL THESE
PROBLEMS IS
5S
5S is a philosophy and a way of organizing and managing
the workspace and work flow with the intent to improve
efficiency by
 Eliminating waste
 Improving Flow
 Reducing useless process.
It is for improvement of working
environment
BY ENHANCING
• HOUSEKEEPING TECHNIQUE
• PRODUCTIVITY
• SAFETY
• 5S activities are to create good working environment through
reduction of “Muri”, “Mura”, and “Muda”
• It help to have a basis of strong management of workplace
Muri Overburden: give unnecessary stress to our employees and our
processes.
• This is caused by Mura and a host of other failures in our system such
as lack of training, unclear or no defined ways of working, the wrong
tools, etc.
Mura unevenness or inconsistency
Muda • activity which is wasteful or doesn’t add any value
• a physical waste of your time, resources and your money
Ex transportation, motion etc.
1. SORTING (SEIRI)
 Focuses on eliminating unnecessary items from the workplace
 Categorize Equipment, Furniture, Tools in your workplace into
categories:
 Remove items which are broken, unusable or only occasionally
used
• Not needed at all • Needed but not now
• Needed but not here • Needed but in limited quantity
EXAMPLE OF SORTING
• Place “RED TAG” for categorization of items to
identify unnecessary items
• Move unnecessary items( broken tools, obsolete jigs
and fixtures, scrap and excess raw material etc.) to
central stored area
• Free up valuable floor space (Space utilization)
• Finding abnormality of equipment and tools (Out of
order, missing parts etc.)
RED TAG TECHNIQUE
GIVE STAFF RED LABELS
ASK STAFF TO GO THROUGH EVERY ITEM IN THE WORK PLACE
ASK IF NEEDED
THOSE THAT ARE NEEDED
IN WHAT QUANTITY
NOT NEEDED
STORE IN THE RED
TAG AREA
RED TAG IT
2. SET (SEITON)
Based on finding efficient and effective storage of necessary items
Apply “Can see, Can take out, and Can return” philosophy
Organise layout of tools and equipment
• Designated locations
• Use tapes and labels
• Ensure everything is available as it is needed and at the
“point of use”
“PLACEFOR EVERYTHING& EVERYTHINGIN ITS PLACE”
EXAMPLE OF VISUAL MANAGEMENT
3. SHINE(SEISO)
oCleaning up one’s workplace daily so that there is no dust on
floors, machines or equipment.
oDivide areas into zones
oDefine responsibilities for cleaning
oTools and equipment must be owned by an individual
It will create ownership and build pride in the workers
Cleaning with meaning Cleaning with inspection
Example of “Shining” activities
Daily sweeping and mopping of floor, bathroom, corridor etc.
Regular cleaning and maintenance of equipment and tools
Periodical check for changes in equipment and the service
area such as:
 leaks
 vibration
 misalignment
 breakage etc.
4. STANDARDISE (SEIKETSU)
Maintenance an environment where first three S are
implemented in same manner throughout the
organisation.
Give opportunities to employees to take active part in
development of these standards
Regularly audit using checklists and measures of
housekeeping
Real challenge is to keep it clean
Example of “Standardize” activities
• Work instructions, Standard Operating Procedures (SOPs)
• Checklist development and regular usage for SOPs
• Mechanism and format development for ordering supplies,
reporting etc
• Colour coding for waste segregation
• Standardized common symbols
5. DISCIPLINE or SUSTAIN
(SHITSUKE)
■ Maintain S1-S4 through discipline, commitment and empowerment
■ Driving force behind all 5S
■ Part of health and safety
■ Involve the whole workforce
 It focuses on defining a new mindset and a standard in workplace
EXAMPLE OF “SUSTAIN” ACTIVITIES
• Regular progress reporting
• Refresher training
• Periodical evaluation of 5S activities with proper advices for
continuation and further improvements
• Appreciation, recognition and awarding on good 5S activities
• Reminder using 5S corner, new letters, good practice sheet
etc.
Zero changeovers leading to product/ service
diversification
Zero defects leading to higher quality
Zero waste leading to lower cost
Zero delays leading to on time delivery
Zero injuries promoting safety
Zero breakdowns bringing better maintenance
Wrap-up
• Positive attitude is very important for implementation
of 5S activities
• It is not “Cleaning Campaign”
• 5S activities are to create good working environment
through reduction of “Muri”(overburden),
“Mura”(unevenness), and “Muda”(waste)
• It is a basis of organization management
1. NEAT & CLEAN WORKPLACE
2. SMOOTH WORKING
3. NO OBSTRUCTION
4. SAFETY INCREASES
5. PRODUCTIVITY IMPROVES
6. QUALITY IMPROVES
7. WASTAGE DECREASE
8. MACHINE MAINTENANCE
9. VISUAL CONTROL SYSTEM
10. EMPLOYEES MOTIVATED
11. WORKSTATIONS BECOME SPACIOUS
5 s ppt by me
5 s ppt by me

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5 s ppt by me

  • 2.
  • 3. WHAT PROBLEMS DO U COMMONLY ENCOUNTER AT YOUR WORKPLACE HIGH ABSENTEEISM HIGH TURNOVER DEMOTIVATED EMPLOYEES DISORDERED/ CLUTTERED ENVIRONMENT MISTAKES/ERRORS
  • 4. THE SOLUTION TO ALL THESE PROBLEMS IS 5S 5S is a philosophy and a way of organizing and managing the workspace and work flow with the intent to improve efficiency by  Eliminating waste  Improving Flow  Reducing useless process.
  • 5. It is for improvement of working environment BY ENHANCING • HOUSEKEEPING TECHNIQUE • PRODUCTIVITY • SAFETY
  • 6. • 5S activities are to create good working environment through reduction of “Muri”, “Mura”, and “Muda” • It help to have a basis of strong management of workplace Muri Overburden: give unnecessary stress to our employees and our processes. • This is caused by Mura and a host of other failures in our system such as lack of training, unclear or no defined ways of working, the wrong tools, etc. Mura unevenness or inconsistency Muda • activity which is wasteful or doesn’t add any value • a physical waste of your time, resources and your money Ex transportation, motion etc.
  • 7.
  • 8.
  • 9.
  • 10.
  • 11.
  • 12.
  • 13.
  • 14.
  • 15. 1. SORTING (SEIRI)  Focuses on eliminating unnecessary items from the workplace  Categorize Equipment, Furniture, Tools in your workplace into categories:  Remove items which are broken, unusable or only occasionally used • Not needed at all • Needed but not now • Needed but not here • Needed but in limited quantity
  • 16.
  • 17. EXAMPLE OF SORTING • Place “RED TAG” for categorization of items to identify unnecessary items • Move unnecessary items( broken tools, obsolete jigs and fixtures, scrap and excess raw material etc.) to central stored area • Free up valuable floor space (Space utilization) • Finding abnormality of equipment and tools (Out of order, missing parts etc.)
  • 18.
  • 19. RED TAG TECHNIQUE GIVE STAFF RED LABELS ASK STAFF TO GO THROUGH EVERY ITEM IN THE WORK PLACE ASK IF NEEDED THOSE THAT ARE NEEDED IN WHAT QUANTITY NOT NEEDED STORE IN THE RED TAG AREA RED TAG IT
  • 20. 2. SET (SEITON) Based on finding efficient and effective storage of necessary items Apply “Can see, Can take out, and Can return” philosophy Organise layout of tools and equipment • Designated locations • Use tapes and labels • Ensure everything is available as it is needed and at the “point of use” “PLACEFOR EVERYTHING& EVERYTHINGIN ITS PLACE”
  • 21.
  • 22.
  • 23. EXAMPLE OF VISUAL MANAGEMENT
  • 24. 3. SHINE(SEISO) oCleaning up one’s workplace daily so that there is no dust on floors, machines or equipment. oDivide areas into zones oDefine responsibilities for cleaning oTools and equipment must be owned by an individual It will create ownership and build pride in the workers Cleaning with meaning Cleaning with inspection
  • 25.
  • 26. Example of “Shining” activities Daily sweeping and mopping of floor, bathroom, corridor etc. Regular cleaning and maintenance of equipment and tools Periodical check for changes in equipment and the service area such as:  leaks  vibration  misalignment  breakage etc.
  • 27. 4. STANDARDISE (SEIKETSU) Maintenance an environment where first three S are implemented in same manner throughout the organisation. Give opportunities to employees to take active part in development of these standards Regularly audit using checklists and measures of housekeeping Real challenge is to keep it clean
  • 28.
  • 29. Example of “Standardize” activities • Work instructions, Standard Operating Procedures (SOPs) • Checklist development and regular usage for SOPs • Mechanism and format development for ordering supplies, reporting etc • Colour coding for waste segregation • Standardized common symbols
  • 30.
  • 31. 5. DISCIPLINE or SUSTAIN (SHITSUKE) ■ Maintain S1-S4 through discipline, commitment and empowerment ■ Driving force behind all 5S ■ Part of health and safety ■ Involve the whole workforce  It focuses on defining a new mindset and a standard in workplace
  • 32.
  • 33. EXAMPLE OF “SUSTAIN” ACTIVITIES • Regular progress reporting • Refresher training • Periodical evaluation of 5S activities with proper advices for continuation and further improvements • Appreciation, recognition and awarding on good 5S activities • Reminder using 5S corner, new letters, good practice sheet etc.
  • 34.
  • 35. Zero changeovers leading to product/ service diversification Zero defects leading to higher quality Zero waste leading to lower cost Zero delays leading to on time delivery Zero injuries promoting safety Zero breakdowns bringing better maintenance
  • 36.
  • 37.
  • 38.
  • 39. Wrap-up • Positive attitude is very important for implementation of 5S activities • It is not “Cleaning Campaign” • 5S activities are to create good working environment through reduction of “Muri”(overburden), “Mura”(unevenness), and “Muda”(waste) • It is a basis of organization management
  • 40. 1. NEAT & CLEAN WORKPLACE 2. SMOOTH WORKING 3. NO OBSTRUCTION 4. SAFETY INCREASES 5. PRODUCTIVITY IMPROVES 6. QUALITY IMPROVES 7. WASTAGE DECREASE 8. MACHINE MAINTENANCE 9. VISUAL CONTROL SYSTEM 10. EMPLOYEES MOTIVATED 11. WORKSTATIONS BECOME SPACIOUS