2. Sundaram-Clayton Limited Slide Number: 2
5S Improvement management
How to diagnose a company?
Look at its 5-S first
No TQM ,TPM or Lean without 5-S
3. Sundaram-Clayton Limited Slide Number: 3
5S Improvement management
Understanding of 5S
1S - Sorting out
2S - Set Limits & Systemize
3S - Shine equipment
4S - Search time elimination
5S - Set standards, Practice & Discipline
Purpose of 5S improvement management is to discipline
ourselves, conduct daily audits and take corrective action(i.e)
find non-conformity,abnormality,deviation,discrepancies and
take immediate corrective action by self
4. Sundaram-Clayton Limited Slide Number: 4
5S Improvement management
1S - Sorting out
Change from wet to dry –
• Nothing on the floor, table, top of racks, cup-boards,
gangways, roadways etc
• If no swarf, water ,oil, dust, paper, litter, potholes etc are
found then it is called Dry
Keep only wanted items for the day’s requirement and remove
unwanted items to the designated areas such as stores,Filing
cabinet,suppliers as the case maybe
Keep only useful items and remove not useful items to
designated areas such as as Red-tag area,scrap yard
No mix up of parts and products in pallets,in racks,in drawers,
bins etc
5. Sundaram-Clayton Limited Slide Number: 5
5S Improvement management
1S - Sorting out
Example : Wet to Dry; Nothing on the floor and gangways
6. Sundaram-Clayton Limited Slide Number: 6
5S Improvement management
1S - Sorting out
Example : Wet to Dry; No potholes,no litter
7. Sundaram-Clayton Limited Slide Number: 7
5S Improvement management
1S - Sorting out
Example : Wet to Dry; Only wanted items
8. Sundaram-Clayton Limited Slide Number: 8
5S Improvement management
1S - Sorting out benefits
Good house keeping (Hospital clean,Garden green
atmosphere)
Pleasant and conducive atmosphere
Facilitates thinking and idea generation for improvement
Keeping all things in order
Facilitates visual control and corrective action
9. Sundaram-Clayton Limited Slide Number: 9
5S Improvement management
2S - Set limits & Systemize
A place for everything: every useful thing has a place
To discipline and work within marked boundaries
Prefixed locations/markings
10. Sundaram-Clayton Limited Slide Number: 10
5S Improvement management
2S - Set limits & Systemize - Examples
Gang-Way marking in shop floor
Curb stones in roadway
Dedicated containers - easy for identification, traceability and
counting
Containers with separators - No parts touching each other to
prevent dents/damages
Pre fixed location in shop floor/office (tools,fixtures,gauges etc)
11. Sundaram-Clayton Limited Slide Number: 11
5S Improvement management
2S - Set limits & Systemize –Examples (Contd.)
X R Chart for quality
Metal temperature, die temperature control limits in
Foundry
Recipe for cooking in kitchen
Fixed number of shots between die-servicing in Foundry
Fixed tool regrinding frequency and operate accordingly
15. Sundaram-Clayton Limited Slide Number: 15
5S Improvement management
2S - Set limits & Systemize
Example: Containers with Separators
16. Sundaram-Clayton Limited Slide Number: 16
5S Improvement management
Before
After
2S - Set limits & Systemize
Example: Pre fixed location
17. Sundaram-Clayton Limited Slide Number: 17
5S Improvement management
2S - Set limits & Systemize
Example: Pre fixed location
18. Sundaram-Clayton Limited Slide Number: 18
5S Improvement management
2S - Set limits & Systemize - Benefits
Prevents accidents,improves safety
Helps to optimize and achieve best in quality, cost and delivery
Facilitates clear cut visual controls
Easy to observe and take corrective / preventive actions
Lead time reduction
Good discipline
19. Sundaram-Clayton Limited Slide Number: 19
5S Improvement management
3S - Shine equipment
Refurbishing of facilities, systems to ensure continuous
improvement
Revising product,processes,methods for enhancing life cycle
Audits for correction and prevention
20. Sundaram-Clayton Limited Slide Number: 20
5S Improvement management
3S - Shine equipment - Examples
Cleaning of machines. Equipment cleaning is checking
Preventive maintenance activities
Poka yoke implementation
Oil,water recycling and reusing
Oil reclamation from wet swarf
Reclaiming aluminium from dross
Replacement of spares/ machinery
21. Sundaram-Clayton Limited Slide Number: 21
5S Improvement management
3S - Shine equipment-Examples (contd.)
Revisiting tools,methods,processes and cells for
implementation and improvement
Refurbishing of old files,painted walls,printer cartridges,
uniforms,shoes etc
Reconditioning of machines
Doing things differently
Shop Floor painting
Refilling of oil
Washing components,hands
26. Sundaram-Clayton Limited Slide Number: 26
5S Improvement management
4S - Search time elimination
Transparent storage systems with nomenclature/coding
Well established visual controls
Maximum 2 minute for part/document retrieval
Set up time reduction
Tool change time reduction
27. Sundaram-Clayton Limited Slide Number: 27
5S Improvement management
4S - Search time elimination-Examples
Open filing system
Transparent storage cupboards
Tool cupboards in shop floor
Fixture stand in the shop floor
Color codification for electrical lines, water lines, air lines etc
Live documents in filing and not records
Parts identification, fixture identification in the shop floor
28. Sundaram-Clayton Limited Slide Number: 28
5S Improvement management
4S - Search time elimination
Example: Open filing system – Quick retrieval
30. Sundaram-Clayton Limited Slide Number: 30
5S Improvement management
4S - Search time elimination
Example: Tool cupboards in shop floor
31. Sundaram-Clayton Limited Slide Number: 31
5S Improvement management
4S - Search time elimination
Example: Fixture stand in shop floor
32. Sundaram-Clayton Limited Slide Number: 32
5S Improvement management
4S - Search time elimination-Benefits
Search time reduced to less than 2 minutes
Increase in productivity
Cost reduction
Eliminates Non Value added (NVA) activities
Reduces mental agony
33. Sundaram-Clayton Limited Slide Number: 33
5S Improvement management
5S - Set standards, Practice &Discipline
Standardizing the 4S practices
Continuous audit and revision of standards
Training of concerned in the revised standards
Abolishing unwanted standards
34. Sundaram-Clayton Limited Slide Number: 34
5S Improvement management
5S-Set standard,Practice and Discipline-Examples
Operation Standards ,Limit samples,Quality Control
Process Charts etc
Horizontal deployment of standards
Quality system manual
Gauge calibration standards
Recipe standard for cooking in canteen
36. Sundaram-Clayton Limited Slide Number: 36
5S Improvement management
Process of holding gains
Daily monitoring through audit scores
Improving ownership by allocating areas
Using red tag campaigns
Communicating visually through fixed point photographs
Structured communication
Continuous training of all employees
Periodic audits at all levels
37. Sundaram-Clayton Limited Slide Number: 37
5S Improvement management
Process of holding gains
Motivating through recognition
Encouraging house-keeping projects through Total Employee
Involvement (TEI)
42. Sundaram-Clayton Limited Slide Number: 42
5S Improvement management
Results of 5S Management
5S management helps to achieve:
Reduction in warranty claims
Reduction in assembly rework in-house
Improvement in inventory turn ratio
Reduction in customer end line stoppers
