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This document provides an overview of 5S workplace organization. It defines the 5S methodology as Sort, Set in Order, Shine, Standardize, and Sustain. Examples are given for each step, including identifying unnecessary items during Sorting, using signage and labeling for Systematic Arrangement, and establishing standard procedures during Standardization. The objectives of 5S are listed as improving housekeeping, promoting individual ownership, beautifying the workspace, improving productivity, and providing a foundation for continuous improvement. Overall, the document outlines the 5S methodology to help establish an organized, clean, and efficient workplace.
1S 2S.pdf
- 1. WELCOME TRAINING on Workplace Management -1S Vijay Khonde Lean Manufacturing Consultant
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- 3. What Are 5S? •Seiri : Sorting (Needed, Not Needed) • Seiton : Systematic Arrangement (Place for Everything & Everything in its Place) • Seiso : Cleaning & Inspection while Cleaning (Shine) • Seiketsu : Standardization (Adhering to the laid down procedures consistently) • Shitsuke : Self Discipline (Maintain) 3
- 4. 5S- Objectives 1. ImproveHousekeeping 2. Individual Ownership 3. Beautify by Simple Means 4. Productivity Improvement by saving time, space etc. 5. Provide foundation for continuous improvements 4
- 5. 5S - Principles 1.Elimination of Waste 2. Team Work 3. Attack Root Cause 4. Sustain the movement 5. Human being is not Infallible 5
- 6. Meaning : Distinguishbetween necessary and unnecessary items and eliminate the unnecessary items Activity : Establish a criteria for deciding on Unwanted items Unwanted items can either be disposed off or they can be relocated Success Area saved or percentage of space available Indicator : 6 SEIRI = Sorting
- 7. • Item isnot needed • Item is needed however quantity in stock is more than what is needed for consumption in the near future Seiri = Sorting What is unnecessary 7
- 8. Seiri = Sorting Frequencyof use Storage Method *Things you have not used in the past one year Throw them out *Things you have used once in the last 6-12 months Store at distance OR Keep in store LOW *Things you have used only once in the last 2-6 months Store it in central place in your zone *Things used more than once a month Store it in central place in your zone HIGH *Things used once a week Store near the workplace *Things used daily or hourly Store near the workplace Organization 8
- 9. Seiri = SortingIdentifying Unnecessary 1. Parts & Work in Process (WIP) • Stock of rejected items • Items accumulated over period for rework • Material awaiting disposal decision • Material brought for trial, still lying even after trial Contd.. 9
- 10. Seiri = SortingIdentifying unnecessary 2. Tools, Toolings • Toolings brought for trial, Currently not in use • Worn out bushes, liners, toggles etc. Lying unattended • Broken tools, bits indisposed 3. Shelves and Lockers • Shelves and lockers tends to collect things that nobody ever uses , like surplus, broken items etc. Contd.. 10
- 11. Seiri = SortingIdentifying unnecessary 4. Walls and Bulletin Boards • Old out-dated notices which have lost their relevance • Posters or bulletins on wall • Remains of torn notices, Cell tape pieces 5. Computer Hard Disk Many unwanted, outdated, temporary files pile up Contd.. 11
- 12. Seiri = SortingDealing with papers How to reduce papers on your table ? 1. Make a single pile of papers 2. Go through them and sort in following categories a) Immediate action b) Low priority c) Pending d) Reading material 12
- 13. FPP – FixedPoint Photography (Before & After) • Fix the views of every zone ( 1 to 3 views) • Capture picture (photo) from the same point every time • Get suggestions from zonal members & Improve the zones continuously • Capture pictures (photos) every month • Arrange the photos in chronological order • Arrange competition 13
- 14. XYZ Industries -Surrounding Area Status in Jan.2012 100 Sq. M Area made free from removing unwanted material Status in Feb.2012 05.02.2012 20.01.2012 One Cutting m/c shifted in this area which was previously infront of Office Status in March 2012 Arranged Two Welding m/c in this area Status in May 2012 28.05.2012
- 15. WPP – WorstPoint Pictures (Before & After) • Unsafe conditions – Excess / insufficient light – Open / loose electrical joints – Hanging wires, improper parts, accessories – No guards for M/cs, Moving parts, Elect. panels • Mixed material • Obsolete items / tools / dies / gauges / docs • Wet floor • Out of reach points for cleaning 15
- 16. Steps for doingSEIRI Sr What to Do? Who Does it? 1 Identify the Coordinator CEO / Plant Head 2 Identify the Zones Plant Head / Coordinator 3 Identify the Zonal Coordinators Plant Head / Coordinator 4 Identify the Red Tags Holding area Coordinator 5 Define the Red Tag Plant Head / Coordinator 6 Establish criteria for Red Tag CEO / Plant Head 7 Establish frequency for doing Red Tag CEO / Plant Head 8 Do the Red Tag All people 9 Identify the Review committee CEO / Plant Head 10 Review the Red Tagged Items & Record Review committee 16
- 17. Red Tag • Itcan be a paper tag with the following information • What is the item? • How much Qty? • Why is it removed out (damaged, excess etc. • What is the approx. value? • Section from where the item is removed? “Establish the frequency of doing the Red Tag” 17
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- 19. Criteria for RedTag • Every person asks to all the items around his / her workplace • Is this item needed? • If it is needed, is it needed in this Qty? • If it is needed, is it needed very frequently? If the answer is “NO” : Remove it from the Workplace 19
- 20. Red Tag Targets RedTag Targets Types of Items Physical Areas RM, BO, WIP, Assly. parts, SFG, FG Floors, gangways, shelves, warehouses 20
- 21. Disposal Methods Treatment Disposal Throwit away Dispose off as scrap Sell Sell off to others Return Return to suppliers Lend out Lend items to other sections / companies Distribute Distribute to other sections of company on permanent basis Central Red Tag Area Send items to the central red tag holding area for redistribution, storage or disposal. 21
- 22. Practice : 1S • Identify 5 S Coordinator, Zones, Zonal Coordinators & Review Committee. • Display area of zones, photographs of Zonal coordinator and his team members at appropriate place in the zone itself. • Seek help of the Consultant • Identify Red Tag holding area, define Red Tag, establish criteria for Red tag & frequency. • Do the Red Tag as planned, review & record. • Show it to the Consultant & get assessed. 22
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- 25. Red Tagging Campaign Zo ne No. ZoneName Red Tag Found Total Pending Tags Red Tag Found Total Pending Tags Red Tag Found Total Pending Tags Red Tag Found Total Pendin g Tags 01 Office 16 00 04 00 05 02 4 0 02 Press 13 02 06 01 06 04 4 0 03 Co2 Welding 14 03 05 00 05 04 3 0 04 Spot Welding 12 01 03 00 04 03 4 0 05 Packing & Disp. 14 04 03 02 03 03 3 0 06 Surrounding Area 09 00 03 01 03 02 02 0 Total 78 10 24 04 26 18 20 0 16 13 14 12 14 9 4 6 5 3 3 3 5 6 5 4 3 3 4 4 3 4 3 2 Zone 01 Zone 02 Zone 03 Zone 04 Zone 05 Zone 06 1st 2nd 3rd 4th
- 26. Red Tagging Campaign Zone No. ZoneName Red Tag Found Red Tag Cleared Red Tag pending (16 Mar 2012) Total Pending Tags (Cumulative) 01 Office 3 3 00 0+2 =2 02 Press 3 3 00 0+7=7 03 Co2 Welding 3 2 01 1+7=8 04 Spot Welding 2 2 00 0+4=4 05 Packing & Disp. 5 3 02 2+9=11 06 Surrounding Area 2 1 01 1+3=4 Total 18 00 36
- 27. Meaning : Todetermine type of storage and layout that will ensure easy accessibility for everyone . Activity : - Functional storage - Creating place for everything and putting everything in its place Success Time saved in searching Indicator : Time saved in material handling 27 SEITON : Systematic Arrangement
- 28. SEITON • Seiton meansarranging needed items so that they are easy to use and label them so that anyone can find. • It helps eliminate following waste in the workplace – Motion waste – Searching waste – Waste of human energy – Waste of excess inventory – Waste of defective parts – Waste of unsafe condition 28
- 29. The Good, Badand the Ugly First the Bad and the Ugly - Life Without 5S
- 30. Some 5S Examples Before5S After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)
- 31. 5S Examples -Sort, Set in Order See the difference! 1. Sort - All unneeded tools, parts and supplies are removed from the area 2. Set in Order - A place for everything and everything is in its place
- 32. Steps to doSEITON • Step A : Decide Appropriate Location – Principles of storing Jigs, tools, dies – Principles of motion economy – 5 S Map to decide location • Step B : Identify Location – Signboard Strategy – Painting Strategy – Colour coding Strategy – Outlining Strategy 32
- 33. How to achieveSystematic Arrangement ? • Decide where the thing belongs • Decide how the things should be kept • Maintain the discipline of keeping things at the right place 33 SEITON : Systematic Arrangement
- 34. USE : 1 )Signboards 2) Colour Codes 3) Outline Markings 4) Labels 34 SEITON : Systematic Arrangement
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- 42. Usage Frequency • Store frequentlyused material near the workplace and less frequently at some distance Weight & Shape of the Material • Heavy material should be stored at lower levels/layers • Place directly on the material handling device for ease of handling 42 Seiton = Systematic Arrangement
- 43. Seiton = SystematicArrangement Category • Same category of material may be stored in one location e.g. Allen Screws, Oil Seals Operation Wise • All items required for an operation may be stored in one location. e.g. Allen key, Spanner etc. hand tools required for setting m/c 43
- 44. The 2 S- Summary A place for everything and everything in its place, clean and ready to use • Arrange workplace for safety and efficiency – Identify key equipment and supplies – Determine location for each item – Outline locations and zones – Develop shadow boards, label items – Document layout, equipment, supplies
- 46. 5S - BENEFITS Reduction in Wastages M/c Downtime Reduction Better Space Utilization Reduction in Inventory Clear Identification & Traceability Reduced Material Handling 46