Unlocking Radiant Skin: The Ultimate Skincare Guide( beyonist)
5 S
1.
2.
3. History of the 5S Methodology
Thought to be first utilized by Toyota in the 1970s, the 5S Methodology converts
as a Lean Methodology in the US. However, some believe the method is even older than
that.
Where Did the 5S Methodology Begin?
A Internet company called Quality Assurance Solutions reveals that the history of
5S goes back as far as the 16th Century and Venice shipbuilders.
4. Venice:
To explore the history of 5S in quality assurance it is necessary to begin with Venetian shipbuilders of
the 16th century. The Arsenal of Venice during Elizabethan times was a paragon of efficiency in manufacturing.
The enclosed Arsenal employed thousands of shipbuilders and followed an assembly line approach.
Different pieces from which a galley was made were prepared in workshops, ready to be assembled
into a whole ship. Story has it that a 1574 visit from King Henry III of France prompted the shipbuilders to build
an entire galley in the two hours or so in which Henry attended a banquet in the Arsenal's Great Hall. Whether
the ship was sound or not is a matter of conjecture, but it did aptly demonstrate the efficiency of the shipbuilding
operation.
In an effort to streamline the assembly process, workers used quality process production to build ships
in hours instead of days or weeks.
7. Japan:
From there, it was Sakichi Toyoda and son Kiichiro as well as Toyota engineer
Taiichi Ohno who developed the 5S methodology or what they called the Total Production
System (TPS) after World War II.
8. The three Toyota representatives looked at both
Ford Motor Company’s assembly lines and the
inventory process at the supermarket chain Piggly
Wiggly.
9. Through analysis at Ford, they did notice waste
along with workers who had to wait for one step
to be completed which resulted in layoffs and
rehiring.
10. At Piggly Wiggly supermarkets, their inventory system of ordering only
what was needed based on demand helped them understand and implement
the Just-In-Time or JIT process into the 5S methodology.
11. The 5S Methodology formed by Toyota offered each
employee a level of importance and encouragement that every job
was essential to the process and end product. Waste was kept to a
minimum and workspace organization led to timely outcomes with
genuine employee pride.
12. 1. Waste from overproduction
2. Waste from waiting times
3. Waste from transportation and handling
4. Waste related to useless and excess
inventories
5. Waste in production process
6. Useless motions
7. Waste from scrap and defects
For companies not yet in a state of
excellence, wastes are opportunities of gain
the 5S help to harvest.
The seven types of waste according to TOYOTA are:
13. 1. Waste from overproduction
It may sound surprizing, but many companies are producing more than necessary
because they loose parts, products, material! Without order, care and discipline in storage,
inventories will fill all available space. Temporary storing a batch in a non defined /
dedicated area is risky, as someone could move the batch without care nor notice In such a
case, it is likely to loose its track, all ending in a waste of raw material, energy and man
power.
14. It may lead to a double waste if the lost batch
requires to produce a new one be delivered!
Eliminating the wasted space and valuable
surface by excess inventories and
overproduction is another potential
improvement.
5S can be used to setup rules for storing, define
space and places. These rules have to be widely
communicated so that everyone knows where is
what, why and for how long. While
continuously improving the situation, the rules
have to be updated and stick to the newest state.
15. 2. Waste from waiting times
Waiting is a consequence of poor synchronization between process stages or bad
preparation. Waiting for parts, material, tools, instructions, etc... can be caused by a lack
of rules about storage places, when people have to search everywhere.
Are the item you are waiting for realy necessary ? If they're not, if they do not add value
to the job or the product, it it wise to try to eliminate them or at least reduce the wait
time and storage distances.
Computers with plenty and poorly ordered data on hard disk drives slow down.
Did you consider directories and files as candidates for 5S?
Searching for files or documents will cause waiting time.
16. A simple trick will help:
Draw a colored slant line on the
back of the files:
•The place of any missing file is
immediately visible
•A file in wrong place displays a
broken line
Better than numbering, which
requires to read and "translate"
the information, the color
line is a part of visual
management: fast and simple.
17. 3. Waste from transportation and handling
The necessity to move and transport can
be caused by the previously mentioned wastes.
All transportations may not be eliminated, but
they have to be kept to the very minimum.
Looking for a pallet truck to move crates
or pallets is a common occupation in the
workshops. People most often claim for more
trucks, but a proper set of rules, parking areas
and discipline to bring them back after use is
enough to solve availability problems.
18.
19. 4. Waste related to useless and excess inventories
"Useless"! the name itself gives the solution. In
the 5S way, anything that is useless is to be
eliminated.
In case of inventories, the gain is the
value of the goods stored and the regained
spaces, which must be dedicated preferably to
value creating activities.
Paper documents and their numerous copies,
catalogues and calendars of previous years, files
and data, dry and worn out pens and pencils...
all excess inventories!
20.
21. Procedures and work guides which are
not constantly updated are likely to let useless
operations be performed in the process.
Sorting and ordering applies also in the
sequences of the process and the related
documents.
This type of waste is also common in
administration processes and office work. Old
rules still remain even if the causes of their
creation disappeared a while ago. As long as
nobody will update the set of rules, everyone
will carry on, sticking to the olds with
application and discipline(!!).
5. Waste in production process
32. 5S is a system for organizing spaces so work can
be performed efficiently, effectively, and safely. This
system focuses on putting everything where it belongs
and keeping the workplace clean, which makes it easier
for people to do their jobs without wasting time or
risking injury.
33. I. Seiri (Sort)
- is the first step in 5S, it refers to the sorting of the clutter from the other items
within the work area that are actually needed. This stage requires the team to remove all
items that clearly do not belong in the working area and only leave those that are required
for the processes in question.
34.
35. How to implement Seiri?
1.Use red tag to get rid of unneeded items.
2.Store items needed by most people in a common storage area.
3.Assign a person to organize and manage the common storage area.
4.Store items only needed by each individual in his/her own working
area.
5.Organize working / Storage Area.
36. II. Seiton (Systematic Arrangement / Straighten /
Set in Order)
- The practice of orderly storage so the right item can be picked
efficiently (without waste) at the right time, easy to access for everyone. A
place for everything and everything in its place.
37. How to implement Seiton?
1. Identify and allocate a place for all the materials needed for your
work.
2. Assign fixed places and fixed quantity
3. Make it compact
4. Place heavy objects at a height where they are easy to pick from
5. Decide how things should be put away, and obey those rules
38. III. Seiso (Shine / Spic & Span)
- Create a clean worksite without garbage, dirt and dust,
so problems can be more easily identified (leaks, spills, excess,
damage, etc)
39. How to implement Seiso?
1. Identify root causes of dirtiness, and correct process
2. Only one work activity on a workspace at any given time
3. Keep tools and equipment clean and in top condition, ready for use
at any time
4. Cleanliness should be a daily activity – at least 5 minutes per day
5. Use chart with signatures/initials shows that the action or review
has taken place
6. Ensure proper lighting – it can be hard to see dirt and dust
41. How to implement Seiketsu?
1. Standardization of best practices through ‘visual management’
2. Make abnormalities visible to management
3. Keep each area consistent with one another
4. Standards make it easy to move workers into different areas
5. Create process of how to maintain the standard with defined roles and
responsibilities
6. Make it easy for everyone to identify the state of normal or abnormal
conditions – place photos on the walls, to provide visual reminder
42. V. Shitsuke (Sustain)
- Implementing behaviors and habits to maintain the established
standards over the long term, and making the workplace organization the
key to managing the process for success
43.
44. How to implement Shitsuke?
1. Toughest phase is to Sustain – many fall short of this goal
2. Establish and maintain responsibilities – requires leader
commitment to follow through
3. Every one sticks to the rules and makes it a habit
4. Participation of everyone in developing good habits and buy-in
5. Regular audits and reviews
6. Get to root cause of issues
7. Aim for higher 5S levels – continuous improvement
45. What Are The Benefits Of 5S?
1. Less Waste Equals Improved Efficiency
A key principle of 5S is to get rid of items that are not used, and make it easier to
find items that are needed. This gets rid of clutter, unnecessary tools, scrap materials and
unused supplies. It organizes, labels and places close at hand those tools and materials that
are needed on a regular basis. The result is that time is spent more productively and less time
is wasted finding needed tools and materials.
In 5S, materials, tools, machines and equipment are positioned in ergonomic locations. This
helps reduce fatigue, quickens access, and results in a more efficient workplace. Ergonomic
positioning helps to address and eliminate the seven wastes.
Standardization is also a part of 5S. Standardization ensures that the most efficient work
practices are identified and used, and that wasteful work practices, unnecessary tools,
unused materials are eliminated.
46. 2. Less Space Used For Storage Equals Reduced Costs
By eliminating unused materials, tools and equipment, and getting rid of clutter,
a surprising amount of space will free up. There is a cost associated with space, not only
in the rental or lease costs, but in heating/cooling, cleaning and maintaining of that
space.
47. 3. Clean Equals Improved Maintenance & Less Down Time
When machines, equipment, and tools are kept clean and free from clutter, it is
easier to spot defects, part failures, and problems such as an oil leak. This allows
preventative maintenance to address the problem before it becomes a more serious
problem.
For example,
If a machine is kept clean, an oil leak would immediately be noticed. The source
and cause of the leak can be quickly identified and the problem fixed, before low oil
levels lead to more serious damage to the machine.
48. 4. Improved Safety
Cleanliness ensures spills get cleaned up ASAP, eliminating the potential for slips and falls.
Clutter is removed, revealing hidden electrical, chemical or mechanical hazards.
Having needed tools, materials and supplies close to where they are needed greatly reduces
travel (movement) and as a result reduces the potential for injury.
Unsafe practices are eliminated through the standardization step of 5S
Employees who have their eyes open for spotting ways to improve using 5S principles will
be more aware of their surroundings and potential safety hazards.
49. 5. Improved Morale Equals Greater Commitment to Job
The clean, organized workplace that results from 5S is a more pleasant workplace
that leads to improved employee attitudes. The focus on cleanliness, organization, labor-
saving efficiency, having the right tools, and using quality standards leads to an increased
pride in workmanship.
