9. Why 5s
What is Waste
• Lean thinking aims to remove wastes from work processes.
• Waste is any action or step in a process that does not add
value to the customer.value to the customer.
• Value adding time vs Non Value Adding time
• Generally its considered 5% vs 95%
• 5s helps in reducing waste
10. Order a Dosa
Step Task Time
1 Enter a Restaurant 9:00 am
2 Sit at a table 9:01
3 Wait for a person, order a dosa 9:02
4 Dosa Arrives 9:10
5 Ask for more sambhar , wait 9:155 Ask for more sambhar , wait 9:15
6 Finish eating, move to wash hands 9:18
6 Ask for Bill 9:20
7 Bill arrives 9:21
8 Cash change 9:24
9 Leave the hotel 9:25
Value Added time is the time we enjoy our dosa, all others are non valued added time.
15. Lets see Waste @ Home
Waste Waste Example
T Transportation walking inside the kitchen from one side to another , searching
items/materials - eg searching knife
I Inventory Excess Kitchen inventory , more than required quantity ,expires or not used. Eg
– extra bread packets, expires soon
M Motion Unnecessary movement(walking, lifting, reaching, bending, stretching, and
moving.) inside the kitchen, not proper layout. eg searching for nail cutter, tvmoving.) inside the kitchen, not proper layout. eg searching for nail cutter, tv
remote,etc
W Waiting Waiting for others arrival, delivery boy, Waiting for others in the home to
complete a task. eg – waiting for guest to arrive.
O Over production Excess food preparation ,eg– more boiled rice than required
O Over processing Doing more than required. Adding more stuff, Ex- getting ready to go out
D Defect/Rework Mistakes. eg -Less salt , or excess salt in food
U Un Utilized Human skills Not applying our mind , feedback/improvement ignored. Eg. Not looking for
improvement.
17. Don't do 5s for beautification sakeDon't do 5s for beautification sake
only if you want to Reduce Waste
18. What is 5s
“5 S”
is the practice of keeping theis the practice of keeping the
workplace organized, free of
clutter & clean
at all times
19. Japanese words
S Japanese Term English Equivalent
1 SEIRI Sort / Tidiness
2 SEITON Set / Orderliness2 SEITON Set / Orderliness
3 SEISO Shine / Cleanliness
4 SEIKETSU Standardize
5 SHITSUKE Sustain / Discipline
20.
21.
22.
23.
24. 1s - Identifying and sorting out the items as
wanted & unwanted
Aim – Save Space Area
Areas
Old/small size shoes @ shoe rack
Dress worn out/smaller size @ cupboards
Old paper/unwanted note books
Broken toys/digital gadgets
Expired/very old item/packets/vessels in kitchen
Computer , mobile , email inbox(0)
25. Red Tag
• Items are red tagged to eliminate what is
unneeded or does not belong in your
workspace
28. 1s Benefits
• Less clutter
• More Space - square feet area available
• More Space – Computer/mobile/inbox
Tips
• Monthly once – fix a date to do 1s.
• Use/Repair/Discard/Store for memories –
Decide , don't keep postponing.
29. Question
• Which area in your house has lot of junk
items/old/messy badly needs 1s sorting ?items/old/messy badly needs 1s sorting ?
30.
31. 2s - A Place for Everything ..
And Everything In its Place – PEEP
Aim – Reduce Motion Waste
Areas
Library
Store Room
Kids Study areaKids Study area
Shoe Rack
Kitchen
Every where ,where an item is stored/retrieved.
Any item should be retrieved in less than 30 seconds
No Searching
32. Question
• Which item do you search for the most (again
and again ) in your house ?and again ) in your house ?
46. Kids Study Rack
• A4 sheet , Text books, Class notes , School
Dairy , Calculator , pencil/ geometry box,
tuition note,etc
• Vertically stack everything , not horizontally• Vertically stack everything , not horizontally
< Before
> After
53. Men’s Wardrobe
Divide (pockets) areas inside the cupboard with Labels
• Office Wear
• Full sleeves
• Half Sleeves
• Formal Pants
• Khaki Pants
• Blazers
• Tie
Rarely used
• Tie
• Jeans
• Shorts
• Dhoti
• Sweaters
• Swim Wear
• T shirts round neck
• T Shirts with collar
• Tailoring required
• Size does not fit(but wanted)
Regularly used
Very Rarely used
Rarely used
58. 2s Benefits
• Easy Retrieval
• Retrieve any item in < 30 seconds
• No searching tension
• Less inventory• Less inventory
• Neat and organised space
• Visual Control – Abnormality shown
59.
60. 3s - That Spick and Span Cleanliness
is Ensured
Aim – Minimize Machine/Workarea Breakdowns
• Daily regular Cleaning
• Cobweb , deep cleaning
• Water tank cleaning
• Air Conditioner filter Cleaning• Air Conditioner filter Cleaning
• Fan/Lights
• Sofas
• Fridges – inside , backside
Cleaning every corner area/equipments in the house Proactively.
65. 3s Benefits
• Clean and neat home
• Cleaning with inspection
• Lesser breakdown of machines
• Cleaning with Responsibility / Ownership• Cleaning with Responsibility / Ownership
66.
67. 4s - Standardize your activities and procedures, so
that 1s,2s,3s are ensured.
Aim – Standardize & Discipline
• Schedules / To Do
• My Area, My Machine concept
OPL – one point lesson• OPL – one point lesson
• Do and dont’s
• Audit
• Matrix for 5w 1h
68. My Area, My Machine
• Entire home , inside , outside , boundaries –
who takes care.
• Kids
• No man’s Land.• No man’s Land.
73. Water tank cleaning schedule
Name Date Jan-2020 April-2020 July-2020 Oct-2020
Sump Plan 15/1/2020 15/4/2020 15/7/2020 15/10/2020
Sump Actual 20/1/2020
Over Head
tank
Plan 18/1/2020 20/4/2020 20/7/2020 20/10/2020
Over Head
tank
Acutal 22/1/2020
76. Dining Table Manners
• No TV, Gadgets While
Eating
• Have Bath before
Breakfast Eating
• No Feeding , Use your
own Hands
• Don't Spill
• Don't Waste Food
Breakfast
• Proper Hand Wash
before/after a meal
• Put your Plate in the
Sink
78. Need for Audit ?
Machinery or Men or Methods(Process), if left alone ,Machinery or Men or Methods(Process), if left alone ,
tend to deteriorate, so have to be monitored
Let it be a Kid or Air conditioner or the way we do a activity –
measure, monitor and improve
79. 5S Sl. No. Checking Item 5S
S1 1.1 Cupboards / Filing Cabinet No irrelevant reference materials such as documents, minutes of meetings, etc are found
S
O
R
T
1.2 Tables / Desks No irrelevant materials on tables/desks or in the drawer
1.3 Stationery Items
Stationery items other than prescribed as standard are not generally kept, excess such as pens, pencils,
staplers, etc
1.4 Stairway / Corners Stairway, Corners, Top of Racks are free of Items
1.5 Red Tagging Unwanted and items required to be relocated are tagged with Red Tag.
S2 2.1
Labels for Storage
equipments
Labeling of Cupboards / Filing Cabinets / Lockers and Office Equipments allows immediate identification
S
E
T
I
N
O
R
D
E
R
2.2 Labels for office equipments and documents
Every thing is clearly identified with
company’s label and standard file labels are fixed.
2.3 Ease of Use Storage is designed for ease of use on the basis of frequent, occasional and rare reference.
2.4 Orderly Storage
Everything is stored in its allotted place and is accessible to all in the department except confidential
documents.
2.5 Aisles and Display Areas All dividing lines and bulletin boards are clearly indicated for Equipment, Aisleways
S3 3.1 Cleaning Responsibilities Person responsible for ensuring cleanliness is identified and is aware of his duties
3.2 Dust and Dirt Windows, window sills, partitions, tables, etc are clean
S
H
I
N
E
3.2 Dust and Dirt Windows, window sills, partitions, tables, etc are clean
3.3 Floor The floor is clean
3.4 Waste Baskets There is a system for disposal of waste paper and other items on a regular basis
3.5 Awareness about cleanliness
Everyone in the Zone is aware of importance of cleanliness and practices it with respect to his
surroundings and zone
S4 4.1 5S Audit Internal audit is carried out and evidence is shown in the Radar chart kept in 5S Zone Board
S
T
A
N
D
A
R
D
I
Z
E
4.2 Internal Auditors List of trained Internal auditors is available and Self audit is carried out every month
4.3 OPL and Visual Control OPL is available for machine handling, Visual controls are available in zone
4.4 Standard 5S practice Daily checklist and regular Patrol is carried out.
4.5 Fire Extinguishers There is a system for maintaining Fire Extinguishers and other Emergency Handling Procedures
S5 5.1 Training
5S awareness training is given to all
employees including contract persons
S
U
S
T
A
I
N
5.2 Voluntary participation
Everyone makes an effort to take active
part in following 5S practices
5.3 5S Kaizens and Suggestions Employees are taking part in giving suggestions and Kaizen for 5S improvements
5.4 5S ZONE Boards 5S zone board is maintained with information related to 5S and getting updated from time to time
5.5 Intra unit competitions 5S competitions are conducted periodically to select Best Zone and Best 5S Employee.
80.
81. 5s
Aim –Continuous Improvement Culture
• Kaizen
• Quality Circle
• Lean
• Total Employee Involvement/Engagement• Total Employee Involvement/Engagement
• Competitions -internal and external
• Proactive Team
82. Kaizen @ home
• Smaller improvements
• Reduce waste , resources , material
• Reuse, Reduce, Recycle
• Save EnvironmentSave Environment
• Rain water harvesting, RO reject water to garden
83.
84.
85. Who all Can do 5s ?
Every One Every WhereEvery One Every Where
86.
87. 5s inside Mobile
S English Equivalent To Do
1 Sort / Tidiness
Clear old/unwanted photos,videos,forwards, save
space
2 Set / Orderliness
Create folders , files , bucket apps – folders, photos,
2 Set / Orderliness
Create folders , files , bucket apps – folders, photos,
speed dial, quickly get what you want.
3 Shine / Cleanliness Clean , inspect, memory cleaner
4 Standardize
Backup, sync plans, schedule backup methods,
update os,apps
5 Sustain / Discipline
Monitor time spent , manage distractions, mobile
discipline (does mobile help us grow or time
wasters)
88.
89. Japanese words
S Japanese Term English Equivalent Respect
1 SEIRI Sort / Tidiness Space
2 SEITON Set / Orderliness Time2 SEITON Set / Orderliness Time
3 SEISO Shine / Cleanliness Workplace
4 SEIKETSU Standardize Safety
5 SHITSUKE Sustain / Discipline Society
90. Why ?Why ?
To Reduce Waste(inefficiencies)
Waste Reduced is Profit Added
Inefficient people will lose jobs
inefficient business will vanish
91. 5s is a Journey not a Destination
Don't Wait for the Right time , Start Somewhere
93. 5s Work Place References
• ABK AOTS Chennai –
http://abkaotschennai.com/
• QCFI• QCFI
• https://qcfi.in/
• CII 5s Awards
94. Check this link for our
5s Presentations
5s Pillars of Visual Workplace book - Mind map
https://bit.ly/salemgopi5s
https://www.facebook.com/salemgopihosp