1. NATHAN & NATHAN
CONSULTANTS PVT LTD
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PROCANDOUR AUTOMOTIVE
SYSTEM PRIVATE LIMITED
WELCOMES THE PARTICIPANTS
FOR WORKSHOP ON 5S
PRACTICES
2. NATHAN & NATHAN
CONSULTANTS PVT LTD
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INTRODUCTION
• NEED FOR 5S
• HOUSEKEEPING LEVELS
• BENEFITS OF 5S
PRACTICES
• BASIC CONCEPTS OF 5S
• BENEFITS
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CONSULTANTS PVT LTD
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What is 5S ?
• An essential step required for Waste
Elimination
• An integral step in Kaizen
• A required element to achieve Lean-site
Manufacturing
Standardization/Perseverance
“Shitsuke”
Systematic
Organization
“Seiri”
Orderliness
“Seiton”
Cleanliness
“Seiso”
Cleanup
“Seiketsu”
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CONSULTANTS PVT LTD
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WHY ‘5S’?
• Helps in TPM Implementation
• Reducing M/C Downtime
• Safety
• Establishes an Ambience for Quality
• Creates a Healthier Corporate Climate
• Better Operational Control of Process
• It is a Scientific Method for Good
Housekeeping
5. NATHAN & NATHAN
CONSULTANTS PVT LTD
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HOUSEKEEPING
Housekeeping is a process wherein everyone
in the company is committed to and involved
in up keeping of the workplace and
cleanliness of m/c, material etc., such that
only needed material is kept and it’s fastest
accessibility is ensured
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CONSULTANTS PVT LTD
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5 LEVELS OF HOUSEKEEPING
• Level 1: - Floor is full of unwanted material
• Level 2: - Clutter found by the walls
• Level 3: - Factory / office is clean but tools,
papers, files & material disorganized
• Level 4: - Storage area, m/c, offices are clean &
furniture, documents and material organized
• Level 5: - Factory / office is immaculate
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CONSULTANTS PVT LTD
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5 PILLARS OF VISUAL
WORKPLACE
‘5S’s are the five keys to Total Quality
Environment. These are:
SEIRI - Sorting Out
SEITON - Arrangement (Systematic)
SEISO - Spic and Span (Cleanliness)
SEIKETSU - Standardization (Neatness)
SHITSUKE - Discipline (-Self)
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CONSULTANTS PVT LTD
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RESISTANCE TO IMPLEMENTING
THE 5 PILLARS
• What is so great about Organisation &
Orderliness. (O&O)
• Why clean when it just gets dirty.
• Implementing O&O will not boost output.
• We have already implemented O&O.
• We did the 5 Pillars years ago.
• We are too busy to spend TIME ON O&O.
• Why do we need to implement 5 Pillars?
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CONSULTANTS PVT LTD
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BENEFITS TO INDIVIDUAL
•Pleasant and Clean workplace
•Make your job more satisfying
•Remove many obstacles and frustration
in your work
•Help you to know your work and also
when and where to do it
•Makes it easy to communicate
•Kindle your Creative Thinking
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CONSULTANTS PVT LTD
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SEIRI (Sorting Out)
Meaning:Putting things in order, Sorting,
Removing what is not needed and keeping what is
needed.
Activities: Sort through and then sort out
Sort through what you have,
Identify which are all required,
Discard what is unnecessary &
Dealing with the causes of filth.
House Cleaning
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CONSULTANTS PVT LTD
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SEIRI : Guidelines
• Things we don’t use: discard.
• Things We don’t use but want to have on hand
just-in-case:
• Keep as contingency items.
• Things we use only infrequently: store somewhere
far away
• Things we use sometimes: store in workplace
• Things we use frequently: keep at workplace or on
the person
18. NATHAN & NATHAN
CONSULTANTS PVT LTD
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PROBLEMS FACED
When Workplace is not organised properly the following
problems arise-
• Shop-floor more crowded and hard to work in
• Storage cupboards and lockers between machines create
walls thereby affecting communication
• Time lost while searching for parts, tools etc.
• Excess inventory of parts, tools and machine result in
increased cost.
• Stock in hand hides other types of problems in production
• Unwanted items in shop-floor make it harder to improve the
process flow.
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CONSULTANTS PVT LTD
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IMPLEMENTING FIRST ‘S’ RED
TAG STRATEGY
•Red Tag is put on all items to be identified
•When identified, evaluate and decide
•Decisions could be
•Hold in Red Tag Holding Area for sometime
to decide whether they are needed or not
•Disposed
•Relocated
•Left in the shop where they are
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CONSULTANTS PVT LTD
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STEPS IN RED TAGGING
•Launch Red Tag Project
•Identify Red Tag targets
•Set Red Tag criteria
•Make Red Tags
•Attach Red Tags
•Evaluate Red Tagged items
•Document the results of Red Tagging
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CONSULTANTS PVT LTD
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RED TAG TARGETS
• EQUIPMENT
– Machines
– Equipments
– Jigs and Tools
– Cutting Tools
– Gauges
– Carts and handling
– Worktable
– Cabinets, desks, chairs
• PHYSICAL AREAS
– Production area
– Walkways
– Walls,shelves
– Warehouses
• INVENTORY
– Raw material
– In Process
– Sub Assembly
– Semi Finished
– Finished
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CONSULTANTS PVT LTD
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DISPOSAL METHODS
•Throw away - as scrap or incinerate
•Sell
•Return to source
•Lend to other departments-Temporary basis
•Distribute to other Units-permanent
•Central Red Tag area for decision
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CONSULTANTS PVT LTD
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TYPES OF UNWANTED ITEMS
•Defective or excess parts
•Obsolete or broken Jig, tools & gauges
•Worn out tools
•Old rags and cleaning supplies
•Unsafe or broken electrical units
•Outdated poster, signs,notices & memos
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CONSULTANTS PVT LTD
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PLACES WHERE UNWANTED
ITEMS ACCUMULATE
• No man’s Land
• Corners near entrance and exit
• Along interior & exterior walls, next to partitions &
behind pillars
• Under the eaves of warehouses
• Under desk, shelves and cabinets
• Unused exhibit boards
• In Tool Boxes which are not clearly sorted
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CONSULTANTS PVT LTD
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‘SEITON’: Systematic Arrangement
Meaning: Keep things in such a manner that people can
reach them easily whenever they need.
– Design/plan Functional Storage based upon 5W1H
– Create place for everything & everything in it’s
place
– Keep accessibility as easy as possible, also
minimum material handling
– Zoning and placement marks
– First In First Out (FIFO)
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CONSULTANTS PVT LTD
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PRINCIPLES OF STORING JIGS,
TOOLS & DIES
• FREQUENCY OF USE.
• SEQUENCE OF USE.
• EASE OF HANDLING.
• VARIETY ELIMINATION OF JIGS & DIES.
• STORE TOOLS BY PRODUCT.
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CONSULTANTS PVT LTD
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PRINCIPLES OF MOTION
ECONOMY
• START AND END EACH MOTION WITH BOTH HANDS
MOVING AT ONCE.
• USE GRAVITY INSTEAD OF MUSCLE
• AVOID ZIGZAG AND CHANGE IN DIRECTION
• USE FOOT OPERATED SWITCHES
• KEEP MATERIAL AND TOOLS IN FRONT AND IN
ORDER OF USE
• OPERATOR AT PROPER HEIGHT
• POSITION PARTS AND MATERIAL FOR EASY REACH
• PROPER HANDLES AND GRIPS
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CONSULTANTS PVT LTD
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SEISO: (SPIC & SPAN)
Meaning: Keeping things clean and polished, no trash or
dirt anywhere in the workplace.
Activities:
• Clean equipment, tools, furniture, notice boards, records
etc.
• Keep the workplace spotlessly clean.
• Locating (inspection) and attending to minor problems
while cleaning.
• Sweeping, wiping, polishing, painting etc.
• Everybody acting like a caretaker.
• Clean even places most people do not notice
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CONSULTANTS PVT LTD
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SEISO: The Three Approach
• MACRO
• INDIVIDUAL
• MICRO
Cleaning everything and dealing with the
overall causes
Cleaning specific work places and specific
piece of machinery
Cleaning specific parts and tools and the
causes of grime are identified and corrected
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CONSULTANTS PVT LTD
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TYPES OF EQUIPMENT PROBLEM
• OIL LEAKS
• DIRTY - OPERATOR RELUCTANT
• GAUGES AND INDICATORS NOT ACCESSIBLE
AND NOT EASY TO READ
• NUTS & BOOLTS MISSING OR LOOSE
• MOTORS OVERHEAT
• SPARKS FLARE FROM POWER CORDS
• V BELTS LOOSE OR BROKEN
• STRANGE NOISE
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CONSULTANTS PVT LTD
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STEPS IN CLEANLINESS
INSPECTION
• DETERMINE CLEANLINESS TARGETS
• MACHINES & EQUIPMENTS
• JIGS, TOOLS & DIES,GAUGES
• ASSIGN CLEANLINESS INSPECTION JOBS
• MAINLY WORKERS, SUPERVISORS & GROUP
LEADERS
• LARGE SIGNBOARD FOR SHOP & SMALL FOR
EACH M/C
• DECIDE CLEANLINESS INSPECTION CHECKLISTS
• IMPLEMENT CLEANLINESS INSPECTION
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CONSULTANTS PVT LTD
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SEIKETSU: (STANDARDIZATION)
Meaning: Maintaining cleanliness, after cleaning
eliminating germs and stains; also standardization.
Activities:
• Establish management standards for maintaining the
5Ss
• Introduce innovative visible management
• Color coded pipes, warning colors, inspection marks
• Early detection and early action
• Okay marks, Marking on meters
• Belt size labels
• Fire extinguisher signs
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CONSULTANTS PVT LTD
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CONTINUOUS EFFECTIVE
STANDARDISED CLEANUP
• BY TAKING TO NEXT LEVEL OF PREVENTION
USING 5W1H APPROACH
• PREVENTIVE ORGANISATION
• PREVENTIVE ORDERLINESS
• PREVENTIVE CLEANLINESS
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CONSULTANTS PVT LTD
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SHITSUKE: (SELF-DISCIPLINE)
Meaning: Inspiring pride in the workplace and scrupulous
adherence to standards in the other four components
Activities:
• Create good awareness about 5S – Training to everyone
• Develop norms: e.g.., one minute 5S, Exercise time, Group
cleaning
• Preparation of 5S manuals
• Communication and feedback
• Individual responsibility and total employee involvement
• Practicing good habits
• Regular monitoring through audits
• Seeing is believing
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CONSULTANTS PVT LTD
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IMPLEMENTING DISCIPLINE
• AWARENESS OF 5 PILLARS & DISCIPLINE TO
IMPLEMENTATION
• ALLOCATE ENOUGH TIME IN WORK
SCHEDULE FOR 5 PILLAR IMPLEMENTATION
• STRUCTURE TO IMPLEMENT 5 PILLARS
• SUPPORT FROM MANAGEMENT BY WAY OF
ACKNOWLEDGEMENT, LEADERSHIPAND
RESOURCES
• REWARDS AND RECOGNITIONS
• SATISFACTION & EXCITEMENT
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CONSULTANTS PVT LTD
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MANAGEMENT ROLE
• EDUCATING EVERYONE ON 5S CONCEPTS, TOOLS &
TECHNIQUE
• CREATING TEAMS FOR 5S IMPLEMENTATION
• ALLOWING TIME FOR IMPLEMENTATION & CREAT
SCHEDULES
• PROVIDE RESOURCES
• ACKNOWLEDGE AND SUPPORT 5S EFFORTS
• ENCOURAGE CREATIVE INVOLVEMENT BY
ALLWORKERS, LISTENING TO THEM & ACTING ON
THEM
• PROMOTING TANGIBLE & INTANGIBLE REWARDS
• CONTINUOUS PROMOTION OF 5S EFFORTS
(ONGOING)
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CONSULTANTS PVT LTD
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ROLE OF SUPERVISORS &
WORKMEN
• SUPERVISORS & MANAGERS
• IMPROVING QUALITY & EFFICIENCY OF THEIR OWN
WORK
• TEACHING BY EXAMPLE
• DEMONSTRATING COMPANY’S COMMITMENT
• WORKMEN
• CONTINUE TO LEARN MORE ON 5S IMPLEMENTATION
• EDUCATE COWORKERS
• TAKE INITIATIVE TO IMPLEMENT 5S ON DAILY BASIS
• GENERATE CREATIVE IDEAS & INFORM
• 100% EFFORTS IN IMPLEMENTATION
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CONSULTANTS PVT LTD
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BEFORE AND AFTER - 5S
5 S Element Waste/ Improvement Item Deliverable
Systematic Organization Elimination of finding.
Reduction of part selection errors.
Reduced Costs
Improved Quality
Increased Product Options
Sorting-Visual
Placement
Elimination of finding.
Elimination of nonconformances.
Elimination of motion.
Reduction of part selection errors.
Reduced Costs
Increased Safety
Improved Quality
Increased Product Options.
Scrubbing Clean Increased safety.
Preventive maintenance.
Increased equipment knowledge.
Increased Safety
Improved Quality
Standardization Control Increased equipment life.
Higher morale.
Clean environment.
Increased visibility of nonconformances.
Improved Quality
Consistent Delivery
Improved Safety
