5S Module - Key Slides
- 1. 5S - WorkplaceManagement System 1Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving ..
- 2. 5S is aworkplace organization and continuous improvement system 5S is a process for implementing and maintaining a clean, safe, and organized work area 5S is a system uses a list of five Japanese words: Seiri, Seiton, Seiso, Seiketsu & Shitsuke What is 5S ? 2Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. General Concept
- 3. Benefits of 5S: It makes problem visible Prevents deterioration Results in space saving Reduces item retrieval time Reduces inventory of items Eliminates unsafe condition Improves hygiene level High employee morale Improvement in quality Reduction in cost 3Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. General Concept
- 4. • Define whatis and isn’t needed in the area to do the job. Remove items not needed: tools, books, instructions – prioritize essential items SEIRI = Sort • Organize the work area based on ‘A place for everything and everything in its place.’ Designate locations for files, tools, equipment, supplies, etc. and label properly SEITON = Set in Order • Clean, sweep, scrub, etc. Cleaning is inspection.SEISO = Shine • Identify “Best Practices” and document them so they can be followed by everyone. Use same tools, processes, and documentation where applicable. SEIKETSU = Standardize • Maintain and review with everyone involved. Continual reinforcement of the importance of 5S; Audits, Culture change – make it a habit. SHITSUKE = Sustain 4Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? - Basic Definition
- 5. 1S - Seiri(整理 ) : Sort : Sorting 5Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 1st S SEIRI 1) Remove unnecessary items and dispose them properly 2) Make work easier by eliminating obstacles 3) Reduce chance of being disturbed with unnecessary items 4) Prevent accumulation of unnecessary items 5) Evaluate necessary items with regard to usage / cost factors
- 6. 6Creating Value throughPeople & Process Development Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 1st S SEIRI Examples of SEIRI :
- 7. 2S - Seiton(整頓) : Straighten : Set in Order 7Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 2nd S - SEITON 1) Arrange all necessary items in order 2) Make it easy to find and pick up necessary items 3) Ensure first-come-first-serve basis (FIFO) 4) Make work flow smooth and easy 5) Prevent loss and waste of time
- 8. 8Creating Value throughPeople & Process Development Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 2nd S - SEITON Examples of SEITON :
- 9. 3) Seiso (清掃): Cleaning : Shine 9Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 3rd S SEISO 1) To clean the workplace thoroughly so that there is no dirt 2) Use cleaning as inspection (Cleaning with Meaning) 3) Can also be translated as "sweep" or " Spic & Span" 4) Prevent machinery and equipment deterioration 5) Keep workplace safe and easy to work
- 10. 10Creating Value throughPeople & Process Development Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 3rd S SEISO Examples of SEISO :
- 11. 4S - Seiketsu(清潔) : Cleanliness : Standardise 11Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 4th S SEIKETSU 1) Maintain high standards of housekeeping & hygiene at all times 2) Maintain cleanliness and orderliness 3) Maintain everything in order and according to its standard 4) Develop standards for 5S and operational Activities 5) Focus on improving Visual Displays
- 12. 12Creating Value throughPeople & Process Development Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 4th S SEIKETSU Examples of SEIKETSU :
- 13. 5S - Shitsuke(躾) : Sustain Self Discipline 13Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. What is 5S ? – 5th S SHITSUKE 1) keep in working order - ongoing / continuous Improvement 2) Also translates to "Self-Discipline" meaning to do without being told 3) 5S is a habit and it is to be continually improved 4) Keep the 5S going through training, communication & organization structures 5) Allocate time for maintaining, Management Support, Rewards"
- 14. Preparatory Steps toImplement 5S is Pilot Project : Train a Team on 5S – Representation of Top & Middle Management Select a Model Area / 5S Zone Start 5S under direction with Top Management and 5S Coordinator With a small team of with a Small Team Show the results and deploy horizontally 14Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. 5S Implementation
- 15. 5S Structure ofa Process : ABC Limited, India HR S. No Area Area Co-ordinator Zone Zone Leader Sub Zone Sub Zone Incharge PL Office xxxxxxxxx Office / Cubicles xxxxxxxxx Store - 1 xxxxxxxxx Store - 2 xxxxxxxxx Reception xxxxxxxxx Meeting Room xxxxxxxxx Storage Rooms xxxxxxxxx Cooking Area xxxxxxxxx Cleaning Area xxxxxxxxx Dinning Hall xxxxxxxxx Gate Office xxxxxxxxx Weigh Bridge xxxxxxxxx Parking Area xxxxxxxxx Dispensary xxxxxxxxx Prepared By : XXXXXX XXXXXX Approved By : XXXXX XXXXX Date : XX-XXX-XX 2 IPST Abdul Canteen Heera Lal Main Gate Moti Lal 5S Structure and Zone 5S Co-ordinator : Rahul Verma : Imran Khan 1 HR Ram Singh HR Office Panna Lal 15Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. 5S Implementation
- 16. Item Activity Initial ❑ Carryout initial audit and assess present 5S Score ❑ Take as many picture as you can 1S - Seiri ❑ Carry out mega sorting, initial mega drive and later on based on need ❑ Red tag unwanted items and shift them to RED TAG AREA ❑ Dispose, reuse of store Red tag items as per need and policies 2S - Seiton ❑ Arrange for storage of wanted items based on frequency of use ❑ Store required items systematically – safe and easy to use Steps to Implement 5S : 16Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. 5S Implementation
- 17. Item Activity 3S -Seiso ❑ Carry out mega cleaning – 6 side cleaning with meaning 4S - Seiketsu ❑ Do proper labelling, put Visual Control in place ❑ Make Standard for Daily 5S and implement them 5S - Shitsuke ❑ Continue training & development, various competitions ❑ Carry put 5S Audit at regular frequency ❑ Rewards best Zones , Processes and Contributors ❑ Make 5S a Daily Habit and Life Line of system ❑ Enjoy improved work environment & build upon improvements on 5S Systems Steps to Implement 5S : 17Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. 5S Implementation
- 18. Common Findings in1S: Obsolete :- Parts ( Jigs / tooling ) not required as the design has become obsolete Defective :- Parts can’t be used as it is (need some correction) Scrap :- Scrap Items not thrown out Not in place :- Kept at wrong place Unnecessary :- Extra / not useful Mix-up :- Mixed parts .. Needs attention Un-identified :- Nobody’s baby Items not used for last 6 months Obsolete documents, not used but still stored for a long time Others :- Even what is this part ?… Nobody knows 18Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 1st S SEIRI – Sorting
- 19. Basic Guidelines forSorting : Frequencies of use (Period of queuing) Grouping Method of disposal ❑ Used less than once a year Not used Throw away (or discuses with seniors) ❑ Used about once every six months to a year Used infrequently Store in a distance Spot ❑ Used about once in two to six months. ❑ Used about once in a month Used some times Organize and keep in work place ❑ Used about once a week ❑ Used once a day ❑ Used all the time Used often Keep Handy Keep Nearby Easily Identifiable 19Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 1st S SEIRI – Sorting
- 20. Necessary Unnecessary Not necessary now,but maybe in the future Put Red Tag on Not Necessary and Unnecessary Items ❑ Remove non-essential items from work area ❑ Sort through desk drawers, file cabinets, carts, tables, office supplies, materials, paper work, and discard unneeded items ❑ Remove hardcopy items where not needed ❑ Sort computer files the same as hardcopy files – remove outdated and unused folders 20Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 1st S SEIRI – Sorting
- 21. Follow your companyPolicy for disposal of Unwanted Items Unwanted capital Items Look for alternate effective use Check within process Check with other process Check with other units Storage of less frequently used items Store them away from shop floor May keep them in process May keep them in Plant / Engineering Store Follow Spare Part / Raw Material policy Follow material storage policy Basic Guidelines for disposal of Red Tag Items : 21Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 1st S SEIRI – Sorting
- 22. Red Tagging : 22CreatingValue through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 1st S SEIRI – Sorting
- 23. Basic Guidelines forStorage : Check What (Item Identification)?, Where ( Location)? & How Much (Quantity)? When (Time limit)? Before actually practicing ‘2S’ Decide appropriate location for every thing and display identification mark for every location Items stored should have the Identification Mark including purpose of storage & its review date Every thing should be cleaned thoroughly before they are stored at its pre fixed location Location and storage of the items should be easily access to all Clear identification and visibility for the location Training and information to all FIFO should be ensured 23Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 2nd S SEITON – Set in Order
- 24. • Ideally nothingstored more than a step away. • Improve efficiency by eliminating time lost looking for items. One Step Rule: • Organize workplace to allow any tool, information or material to be located and retrieved within 30 seconds. • This includes computer files! 30 Second Rule: • Immediate work area layout to minimize twisting.45 Degree Rule: • Store things above the knees and below the chest.Strike Zone Rule: • Locate heavy items to eliminate bending, stooping or unnecessary arm movements during lifting. The higher the pounds, the closer to the knuckles: Basic Guidelines for Storage : 24Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 2nd S SEITON – Set in Order
- 25. Basic Guidelines forSEISO : Create a spotless workplace Identify and eliminate causes of dirt and grime Remove the need to clean Sweep, dust, polish and paint Eliminating trash, filth, and foreign matters for a cleaner workplace. Cleaning as a form of inspection 25Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 3rd S SEISO – Shine & Sweep
- 26. Basic Guidelines forCleaning : • Six side cleaning for all • Refurbishing everything • Make things easy to clean It means…… • Check Items – to be cleaned • Tools to be used – to be used for cleaning • Frequency of cleaning & inspection – when to clean • Person In charge name – responsibility for cleaning Prepare a check list containing following information: Divide entire work place into small zones Define the responsibility of person ( Area wise) 26Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 3rd S SEISO – Shine & Sweep
- 27. What Is ToBe Standardised : Workstation layout, work area layouts Work in Process (WIP) Sequence of work Cycle time of work Material and tools used Spare and raw material to be stored Quantity and location of items to be stored Color coding, visual marking and displays Items to be cleaned – frequency and responsibility “What, Where, When, Who & How ” of work Basic Guidelines for Seiketsu : 27Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 4th S SEIKETSU - Standardisation
- 28. 5S Activity List: ABC Limited, India TQM Process Name : XXXXXXX Process Co-ordinator : ABCD … XYZ S. No. Zone No. Zone Area / Location / Floor Sub Zone 5S Coordinator Sub Zone Team Members Key Action Points Responsibility Frequency Prepared By : Process Person Date : xx-xxx-xxApproved By : Process 5S Coordinator 3 5S Zones & Activity List 1 2 28Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 4th S SEIKETSU - Standardisation
- 29. Basic Guidelines forShitsuke : Progress monitoring through Audit Scores Improving ownership by Allocating Areas Visual communication through Fixed Point Photography Continuous Training to all employees Periodic Audits at all levels Encouraging house-keeping projects through Total Employee Involvement 5S is not one time activity, it’s a Continuous IMPROVEMENT PROCESS No TQM, AM, ISO.. Kaizen, Projects are possible without 5 S 5S ……. a way of life. 29Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _ 5th S - SHITSUKE
- 30. 5S Audit CheckSheet : ABC Limited, India XYZ - Process 0 1 2 3 4 1 Materials, parts or components 2 Machines and other equipment 3 Jigs and tools 4 Visual control 5 Containers 6 Location indicators 7 Item Indicators 8 Kansans 9 Jigs and tools 10 Material storage 11 Floors & gangways 12 Machines and other equipment 13 Internal box cleanliness 14 Cleaning Responsibilities 15 Habitual cleanliness 16 Concerns sheets 17 Spill kits 18 Operation standards 19 PPE 20 Guard checks & sheets 21 Training 22 Tools and parts 23 Stock control 24 Cleaning routine 25 Product I/d Actual Score : Notes: Score : 0 = Very Poor 1 = Poor 2 = Average 3 = Good 4 = Very Good 5S Audit Check Sheet Total Sustain-Self Discipline Is everyone adequately trained in 5S procedures? (Ask what 5S is) Are tools and parts being stored correctly? Are any Kansans over stocked? Is cleaning routine present & are all tools & materials available? Are all parts clearly identified? Route Cards/Non-Conforming Notes? Standardise Are concerns regularly being generated & acted upon? Are spill kit contents being maintained? Are Operation Standards written, clear and actively used? (Ask an Operator) Is PPE being worn in line with assessment? Have checks been carried out & documentation completed? ShineandSweep Are floors/gangways kept clear, clean and free of waste, water or oil? Are the machines/work surfaces kept clean & free of shavings and oil? Are all boxes being used clean & free from debris? Is the person responsible allocating cleaning duties? (Lead Operator) Is the set standard ( photo ) being maintained? SetinOrder Are Kanban locations clearly marked with correct part no.'s? Are shelves clearly marked with gauge or component no.? Are boxes in correct location and not stacked too high? Are gauges and tools arranged to facilitate picking them up and returning them? Is stock rotation ( FIFO ) being adhered to? SORT Does the area house tubes or components not used on line? Are there any unused machines or other equipment around? Are there any unused gauges, fixtures or similar items around? Is it obvious which items have been marked as unnecessary? Are any unused cardboard or plastic boxes on line? Audit Area : Audit Date : 5S No Check Item Description Score Name of Auditor : 30Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _5th S SHITSUKE – 5S Audit
- 31. 5S Audit Score: ABC Limited, India XYZ - Process Before - Period After - Period 1 After - Period 2 1 Seiri 15 17 17 2 Seiton 12 12 18 3 Seiso 14 15 19 4 Sheketsu 10 11 13 5 Shitsuke 8 10 12 59 65 79 Prepared By : 123 Date : xx-xxx-xx S. No Item 5S Score 5S - Score _ Radar Chart Total Score Approved By : 789 0 5 10 15 20 Seiri Seiton SeisoSheketsu Shitsuke Before _ P1 After _ P1 After _ P2 31Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving .. How to Implement? _5th S SHITSUKE – 5S Audit
- 32. Motivation and Celebration: Ek Pahla Kadam, Take it .. Keep moving .. 32Creating Value through People & Process Development How to Implement? – 5th S SHITSUKE
- 33. Thank You Contact :Dinesh Sharma Cell No. : +91 9589004005, 9589892468 e-mail : dinesh@ekpahlakadam.com e-mail : ekpahlakadam@yahoo.com Connect : facebook.com/ekpahlakadam Website : ekpahlakadam.com Your Queries & Feedback Please 33Creating Value through People & Process Development Ek Pahla Kadam, Take it .. Keep moving ..