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Home 5s
- 1. By Ashok Kumar JAshok Kumar J Executive Director Salem Gopi Hospital Salem 28/04/2020 Interests 5s TQM Data Analytics Quizzing
- 2. Thanks for the photos and the effort Roni, Raki, Sumi and Rajesh – CoimbatoreRoni, Raki, Sumi and Rajesh – Coimbatore Aadhya, Achu and Mahe – Salem
- 3. 5s @ Home From Home to Work This Session focuses only on home
- 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.
- 13. 7 Waste defined by Toyota
- 14. 8th Waste Human Potential
- 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
- 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
- 26. Old Shoes , magazines, unwanted stuff
- 27. Red Tag Corner
- 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 ?
- 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 ?
- 33. Shadow Board • Theromcoal , foam sheet , paint , stickers , Card Board box,etc.
- 35. Kitchen
- 37. Kitchen trays
- 38. Kitchen working space table
- 39. Kitchen Cabinets
- 40. Study Table
- 41. Study Table
- 42. Mark Boundary for printer
- 44. Place for Calculator Made from waste material
- 45. Place for remote, if missing, label shows
- 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
- 47. Why Vertical if any item missing, it should show abnormality
- 48. Library • God • Life • Japan • Habits • Scorecard• Scorecard • TQM • Kids • Cooking • Languages- Tamil/hindi
- 49. Photos • Old photos • Wedding Albums • Kids Birthdays • Google Photos folders• Google Photos folders
- 50. Key stand
- 51. Sports corner
- 52. Shoe Rack , Kids Socks, Big socks
- 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
- 54. Kitchen
- 55. Store Room
- 56. While Eating Place for Mobile
- 57. Files/folders organised inside computer any file should be retrieved < 30 seconds
- 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
- 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.
- 61. Are You Prepared for the Day ? Cleaning with Inspection
- 65. 3s Benefits • Clean and neat home • Cleaning with inspection • Lesser breakdown of machines • Cleaning with Responsibility / Ownership• Cleaning with Responsibility / Ownership
- 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.
- 69. Training @ home
- 70. Documents location / dates due renewal @ Trello board • Birth Certificates • Aadhar • Passport • PAN• PAN • Drivers License • Eb username/pswd • Insurance • Etc
- 71. Documents location / dates due renewal @ Trello board
- 72. Folder Pockets • Warranty Cards • Manuals • Books • Purchase Details• Purchase Details • Spare Keys
- 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
- 74. Contact Details, Service Schedule
- 75. EB Bill Amount, Units Tracking Kaizen to Reduce Consumption
- 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
- 77. OPL- One Point Lesson one page communication
- 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.
- 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
- 85. Who all Can do 5s ? Every One Every WhereEvery One Every Where
- 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)
- 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
- 92. Home References
- 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