5's workshop summary

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5's workshop summary

  1. 1. 5’S WORKSOP SUMMARY5S is a systematic approach to good house keeping. It is gaining a strong supporting most industries in Japantoday, and there is an increasing number of companies which are implementing 5S with greater involvement ofpeople within the organisation.Why is it becoming popular among companies in Japan? Simply because: 1) Workplaces become clean and better organised. 2) Shopfloor and office operation become easier and safer. 3) Results are visible to everyone – Insider and outsider. 4) Visible results enhance generation of more and new ideas. 5) People are automatically disciplined. 6) People become proud of clean and organised workplace. 7) Resultant good company Image generates more business, etc.Some significant benefits observed at companies practising 5S in Singapore include:1. Happier people involvement 7. Better flow of work2. Greater people involvement. 8. Low machine breakdown rates3. Low employee turnover. 9. Low accident rates4. Increased number of suggestions. 10. High yield of materials5. Better use of floor space. 11. High product quality6. Less work-in-progress and inventoriesThe assumption of why 5S is becoming so popular in Japan in recent years and now in other countries today is thatit emphasises a people-oriented and also practice –oriented approach. 5S expects everyone – indeed, everyone toparticipate in it. It is based on the belief that every individual can contribute to improving his workplace where hespends one-third of his life.The study and experience in Japan and Asian countries confirm that the 5S approach makes it happen. Manycompanies in Asian countries – some openly and some quietly- are implementing the 5S concepts and practices insome way or the other.WHAT IS 5S?The concept of good housekeeping has been with the Japanese for a very long time. At home and in school,children are disciplined to adhere to good housekeeping practices. However, it was only in the early 1980’s thatgood housekeeping became a pertinent issue in Japanese industries as companies realised its powerful contributionto productivity and quality improvement.The basic for good housekeeping in Japanese companies is a concept popularly known as 5S. This stands for thefive good housekeeping concepts in Japanese. Corporate office- F 41, GF, Suncity , sector -54, Gurgaon, Haryana-122012. Mob.-09818493659Training Center – B 236, Basement Area, Next to Hotel Radisson Blu, Sushant Lok-1, Gurgaon, Haryana. Tel Nos. -0124-6467521,0124-6467522, Email- info@softskillsworld.com, Website- http://www.softskillsworld.com
  2. 2. 5S Original Japanese Meaning in English IS SEIRI Sort of unnecessary items in the work-place and discard them 2S SEITON Arrange necessary items in good order so that they can be easily picked for use. A place for everything & Everything in its place 3S SEISO Clean your work place completely so that there is no dust on floor, machine and equipment. 4S SEIKETSU Maintain high standard of housekeeping and work place organisation at all times. 5S SHITSUKE Train people to follow good house keeping disciplines autonomously GOOD HOUSEKEEPING PRACTICES THROUGH 5SThe 1st step to Continuous Productivity Improvement:One of the easiest ways to determine a company’s attitude towards improvement is simply to walk around itspremises and observe the housekeeping practices. The reason is that good housekeeping is the first and essentialstep to continuous productivity and quality improvement.If we are observant enough, housekeeping practices often tell us more about a company than any financialstatement. For example, one can judge the level of productivity. Improvement activities from machines handled,work tables organised, inspection points indicated, factory floors swept, machines cleaned, personal items storedand so on.In short, housekeeping practices reflect management’s general attitude towards work for eg: a manager who paysno attention to trash scattered around the factory would influence workers in a manner very different from onewho makes sure that trash is picked up whenever it is found. This seemingly trivia difference would eventuallyshow up as wide difference would eventually show up as wide differences in employee morale, amount of defectiveproducts, number of machine breakdown, routing of materials flow and inventory level.Once we recognise this link, we can then appreciate the needs for good housekeeping. A company with goodhousekeeping practises will have a god foundation for higher productivity, higher quality, reduced cost, greatersafety, higher quality, reduced cost, greater safety, higher employee morale, etc. In contrast, poor housekeepingpractises can lead to disastrous outcomes like industrial accidents, high labour turnover, high defect level and theeventual loss of clients. 5S IN RELATION TO OTHER PRODUCTIVITY APPROACHES:A well planned 5S approach brings about many tangible benefits by itself. It also provides a solid foundation andenvironment for introducing more advanced management technologies. Such as QC circles, Basic industrialEngineering Just in Time productive maintenance and so on. Its relationship with other approaches.Currently, the major of Japanese companies is already practising 5S, although they may call it by some other term.The importance of 5S is so great in Japan that certain consultants refuse to render their service to companies thatdo not practise it. Those who have visited companies practising 5S have been convinced of the benefits andshown an interest in adopting the practises as well. As 5S requires mainly the physical effort and discipline ofemployees and not any understanding of complex theories. IT is one area that a company can embark on with fullconfidence of achieving success once commitment has been made. IT is a task that is everyone’ s responsibility. Corporate office- F 41, GF, Suncity , sector -54, Gurgaon, Haryana-122012. Mob.-09818493659Training Center – B 236, Basement Area, Next to Hotel Radisson Blu, Sushant Lok-1, Gurgaon, Haryana. Tel Nos. -0124-6467521,0124-6467522, Email- info@softskillsworld.com, Website- http://www.softskillsworld.com
  3. 3. Good Housekeeping for Practical Reasons:5S practise in a company is done not merely for aesthetic reasons. Underlying 5S practice at the office orShopfloor is a practice or economic reason. Achieving clean floor and organised racks is not an end in itself. TheUltimate goal of housekeeping through 5S is to reduce the cost of the product by increasing productivity andcontributing to total quality.Take a few e.g.: In organising dies, the chief aim is not to pile them up to achieve a need look. Put the mostfrequently used dies closes to the machine and what we have achieved is an arrangement, which minimiseshandling and hence reduces time wastage.Floor and machines are not cleaned simply for the sake of appearance either. Clean surfaces expose problemssuch as oil leaks and cracks so that corrective actions can be taken as early as possible. Such early detection ofproblems helps to prevent catastrophes. In addition, clean and oil-free floors are seldom tripped or slipped uponwhile clean machines do not break down as often as dirty ones.The removal of clutter along passageways is also done for practical reasons. It prevents obstruction to the smoothtransportation of materials and work-in-progress.In any factory, certain parts, tools and machines are often used in our daily operations while others are not used atall. Often, it is difficult to dispose of good that are unnecessary for production activities because there is thetendency to think that they may become useful in the future. As a result, unused dies and parts may be stored inthe factory even though they are obsolete or are for discontinued production items. These goods should be viewedas waste materials that interfere with streamlined daily production activities. They not only take us space but alsocause unnecessary record keeping and transportation costs.The storage of unnecessary goods hampers production activities by increasing transportation distances and bymaking it difficult to distinguish important items from unimportant ones. Just as we take a bath shower to washoff dirt and sweat, our factory also needs a thorough cleaning periodically in order to get rid of accumulatedwastes. 5S and Discipline in Manufacturing5S is relevant for all industries, be it sales, service or manufacturing. It is, however especially crucial fororganisations in manufacturing sector. It is believed that good housekeeping and workplace organisation aredirectly linked to achieving discipline in manufacturing. If production control maintenance, quality assurance orlayout is not properly done, for eg: the problems can usually be traced back to bad housekeeping and workplaceorganisation. In contrast good housekeeping and work place organisation will result in better compliance toschedules, fewer machine breakdowns, lower defect rates and prompt exposure of problem areas.It is only when 5S practices are diligently implemented that a first-class manufacturing operation can be achieved.Companies will find that it pays to make 5S part of their work culture, such that employees are willing to practisegood housekeeping not only in their own work areas but in others as well. With this foundation, they can proceedto take other measures in their pursuit of excellence. Corporate office- F 41, GF, Suncity , sector -54, Gurgaon, Haryana-122012. Mob.-09818493659Training Center – B 236, Basement Area, Next to Hotel Radisson Blu, Sushant Lok-1, Gurgaon, Haryana. Tel Nos. -0124-6467521,0124-6467522, Email- info@softskillsworld.com, Website- http://www.softskillsworld.com
  4. 4. TANGIBLE RESULTS EXPECTED FROM 5S PRACTICESFROM PEOPLE Employees will be disciplined to be more aware of untidy workplaces and motivated to improve the level of cleanliness. Greater team spirit and cooperation can be built up through involvement of all within an organisation. Employees will be disciplined to follow safer and better ways of work, resulting in lesser risks to accidents. Employees would be more conscious of improvement, which leads to greater efficiency and effectiveness.FROM MACHINES AND TOOLS Machine troubles can be detected at an earlier stage to prevent a major breakdown when machines are cleaned daily by people operating them. Daily cleaning of measuring instruments will ensure accuracy and reliability. Life of machines and tools can be extended significantly when they are handled with care and placed in the designated locations.FROM MATERIALS AND WORK-IN-PROGRESS Flow of materials and work-in-progress will become smoother. Floor space will become organised and possible areas for improvement can be easily identified by quick observation. Inventory of materials and work-in-progress will become clearly visible and easily handled. Materials yield ratios can be improved. Reduced material handling will result.FROM PRODUCTS AND CUSTOMERS Clean workplace will ensure that final products will be free from dust. Sales people will be eager to show customers the plant as a marketing tool 8 CRUCIAL POINTS FOR SUCCESSFUL IMPLEMENTATION OF 5SPOINT 1: PARTICIPATION BY ALL PEOPLE IN THE ORGANISATIONOne day should be set aside for the launching of the programme.6 objectives of whys of 5S programme should be understood by all people in the organisation. 1) A clean workplace is high in PRODUCTIVITY 2) A clean workplace has high QUALITY 3) A clean workplace keeps COST down 4) A clean workplace ensures DELIVERY on time 5) A clean workplace is SAFE for people to work 6) A clean workplace is high in MORALEThe programme would be more effective when it is included in the small group activities like QC Circles. Corporate office- F 41, GF, Suncity , sector -54, Gurgaon, Haryana-122012. Mob.-09818493659Training Center – B 236, Basement Area, Next to Hotel Radisson Blu, Sushant Lok-1, Gurgaon, Haryana. Tel Nos. -0124-6467521,0124-6467522, Email- info@softskillsworld.com, Website- http://www.softskillsworld.com
  5. 5. POINT 2: THE PROGRAMME REQUIRES TOP MANAGEMENT’S COMMITMENT The programmes should be practised during working hours as an authorised programme, but should not be treated as a casual or extra activity during overtime or off duty hours. Everyone should be officially informed of the significance of the programme. The CEO should personally make an official announcement of the launching of the programme at an information-sharing meeting attended by all people of the organisation.POINT 3: THE CEO SHOULD TAKE LEADERSHIP OF THE PROGRAMME The CEO himself should be keen and committed and have a vested interest in the programme. The CEO should not delegate the leadership to other people. The CEO should excise his leadership in the 5S Steering Committee.POINT 4: THE PROGRAMME SHOULD BE SUPPORTED BY ALL Such doubts as “ why are the disposal notice posted for Seiri? Why is 5S important for shop floor improvement? should be eliminated. Each committee member should keep everyone informed of the current progress of 5S implementation on a departmental level. Each committee member should encourage and guide his people for involvement in 5S implementation activities.POINT 5: PROGRAMME SHOULD BE SELF-SUSTAINING Banners, slogans posters and newsletters should be fully utilised to draw attention of everyone to this programme. As easy handbook or a pamphlet illustrating why 5S what is 5S and How to implement 5S should be printed and distributed to everyone. Periodic 5S implementation reviews should be conducted by CEO or an external expert for comments and upgrading the status Quo. Basic in house training and introduction to model companies that have a successfully implemented 5S practice would not only provide the necessary skills but also give an insight into how other companies implement 5S. After the company has attained a certain level of implementation, participation in Inter company 5S competition should provide greater motivation for further improvement.POINT 6: THE CEO SHOULD MAKE A PERIODIC FACTORY TOUR IN PERSON The CEO should tour factory from time to time and point out strengths and weaknesses of 5s implementation in each workplace. The CEO should advise 5S Steering Committee to take corrective actions on the areas identified. The CEO should check the progress of the implementation. The CEO should give recognition to improved or better practises. Corporate office- F 41, GF, Suncity , sector -54, Gurgaon, Haryana-122012. Mob.-09818493659Training Center – B 236, Basement Area, Next to Hotel Radisson Blu, Sushant Lok-1, Gurgaon, Haryana. Tel Nos. -0124-6467521,0124-6467522, Email- info@softskillsworld.com, Website- http://www.softskillsworld.com
  6. 6. POINT 7: THE PROGRAMME SHOULD GENERATE SUFFICIENT IMPACT AT THE INITIAL STAGE: Slow implementation of decision by the %S Steering Committee should be avoided. “Disposal notice” approach for Seirl, which is the first step to 5S, should especially be implemented company wide for a specified time before proceeding to Seiton which is the second step for 5S.POINT 8: - IMPLEMENTATION OF 5S SHOULD GO HAND-IN –HAND WITH OTHER KAIZENPROGRAMMES 5S especially at Seiton required certain Kaizen principles and skills, which can be acquired via external or well- organised in-house training programmes. Seiton requires logical problem solving approaches. In this sense, it can well be a good theme for QC circle activities. Seiton also requires creative ideas from everyone. Therefore it can be tied in with an Employee Suggestion Scheme. Successful implementation of 5S will by itself, bring about various tangible results. It also is a necessary step for a company to go through before implementing advanced management technologies such as TQC, JIT and TPM because 5S will build up a solid foundation for an organised by well- disciplined people through Shitsuke. Corporate office- F 41, GF, Suncity , sector -54, Gurgaon, Haryana-122012. Mob.-09818493659Training Center – B 236, Basement Area, Next to Hotel Radisson Blu, Sushant Lok-1, Gurgaon, Haryana. Tel Nos. -0124-6467521,0124-6467522, Email- info@softskillsworld.com, Website- http://www.softskillsworld.com

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