The document discusses the 5S methodology for improvement management used by Sundaram-Clayton Limited. It describes the 5S principles of sorting, setting in order, shining, standardizing, and sustaining. Examples are provided for how each S has been implemented, such as designating areas for different items and visual controls. Benefits include improved safety, quality, productivity and cost reduction. Continuous monitoring, communication and training are emphasized to maintain the 5S system.

1. Sundaram-Clayton Limited Slide Number: 1
5S Improvement management
5S Improvement
Management
- SCL Experience

2. Sundaram-Clayton Limited Slide Number: 2
5S Improvement management
How to diagnose a company?
Look at its 5-S first
No TQM ,TPM or Lean without 5-S

3. Sundaram-Clayton Limited Slide Number: 3
5S Improvement management
Understanding of 5S
1S - Sorting out
2S - Set Limits & Systemize
3S - Shine equipment
4S - Search time elimination
5S - Set standards, Practice & Discipline
Purpose of 5S improvement management is to discipline
ourselves, conduct daily audits and take corrective action(i.e)
find non-conformity,abnormality,deviation,discrepancies and
take immediate corrective action by self

4. Sundaram-Clayton Limited Slide Number: 4
5S Improvement management
1S - Sorting out
 Change from wet to dry –
• Nothing on the floor, table, top of racks, cup-boards,
gangways, roadways etc
• If no swarf, water ,oil, dust, paper, litter, potholes etc are
found then it is called Dry
 Keep only wanted items for the day’s requirement and remove
unwanted items to the designated areas such as stores,Filing
cabinet,suppliers as the case maybe
 Keep only useful items and remove not useful items to
designated areas such as as Red-tag area,scrap yard
 No mix up of parts and products in pallets,in racks,in drawers,
bins etc

5. Sundaram-Clayton Limited Slide Number: 5
5S Improvement management
1S - Sorting out
Example : Wet to Dry; Nothing on the floor and gangways

6. Sundaram-Clayton Limited Slide Number: 6
5S Improvement management
1S - Sorting out
Example : Wet to Dry; No potholes,no litter

7. Sundaram-Clayton Limited Slide Number: 7
5S Improvement management
1S - Sorting out
Example : Wet to Dry; Only wanted items

8. Sundaram-Clayton Limited Slide Number: 8
5S Improvement management
1S - Sorting out benefits
 Good house keeping (Hospital clean,Garden green
atmosphere)
 Pleasant and conducive atmosphere
 Facilitates thinking and idea generation for improvement
 Keeping all things in order
 Facilitates visual control and corrective action

9. Sundaram-Clayton Limited Slide Number: 9
5S Improvement management
2S - Set limits & Systemize
 A place for everything: every useful thing has a place
 To discipline and work within marked boundaries
 Prefixed locations/markings

10. Sundaram-Clayton Limited Slide Number: 10
5S Improvement management
2S - Set limits & Systemize - Examples
 Gang-Way marking in shop floor
 Curb stones in roadway
 Dedicated containers - easy for identification, traceability and
counting
 Containers with separators - No parts touching each other to
prevent dents/damages
 Pre fixed location in shop floor/office (tools,fixtures,gauges etc)

11. Sundaram-Clayton Limited Slide Number: 11
5S Improvement management
2S - Set limits & Systemize –Examples (Contd.)
 X R Chart for quality
 Metal temperature, die temperature control limits in
Foundry
 Recipe for cooking in kitchen
 Fixed number of shots between die-servicing in Foundry
 Fixed tool regrinding frequency and operate accordingly

12. Sundaram-Clayton Limited Slide Number: 12
5S Improvement management
2S - Set limits & Systemize
Example: Gangway marking

13. Sundaram-Clayton Limited Slide Number: 13
5S Improvement management
2S - Set limits & Systemize
Example: Fixed time for garbage disposal

14. Sundaram-Clayton Limited Slide Number: 14
5S Improvement management
2S - Set limits & Systemize
Example:Dedicated Containers

15. Sundaram-Clayton Limited Slide Number: 15
5S Improvement management
2S - Set limits & Systemize
Example: Containers with Separators

16. Sundaram-Clayton Limited Slide Number: 16
5S Improvement management
Before
After
2S - Set limits & Systemize
Example: Pre fixed location

17. Sundaram-Clayton Limited Slide Number: 17
5S Improvement management
2S - Set limits & Systemize
Example: Pre fixed location

18. Sundaram-Clayton Limited Slide Number: 18
5S Improvement management
2S - Set limits & Systemize - Benefits
 Prevents accidents,improves safety
 Helps to optimize and achieve best in quality, cost and delivery
 Facilitates clear cut visual controls
 Easy to observe and take corrective / preventive actions
 Lead time reduction
 Good discipline

19. Sundaram-Clayton Limited Slide Number: 19
5S Improvement management
3S - Shine equipment
 Refurbishing of facilities, systems to ensure continuous
improvement
 Revising product,processes,methods for enhancing life cycle
 Audits for correction and prevention

20. Sundaram-Clayton Limited Slide Number: 20
5S Improvement management
3S - Shine equipment - Examples
 Cleaning of machines. Equipment cleaning is checking
 Preventive maintenance activities
 Poka yoke implementation
 Oil,water recycling and reusing
 Oil reclamation from wet swarf
 Reclaiming aluminium from dross
 Replacement of spares/ machinery

21. Sundaram-Clayton Limited Slide Number: 21
5S Improvement management
3S - Shine equipment-Examples (contd.)
 Revisiting tools,methods,processes and cells for
implementation and improvement
 Refurbishing of old files,painted walls,printer cartridges,
uniforms,shoes etc
 Reconditioning of machines
 Doing things differently
 Shop Floor painting
 Refilling of oil
 Washing components,hands

22. Sundaram-Clayton Limited Slide Number: 22
5S Improvement management
3S - Shine Equipment
Example: Clean Machines

23. Sundaram-Clayton Limited Slide Number: 23
5S Improvement management
3S - Shine Equipment
Example: Clean Hand wash area

24. Sundaram-Clayton Limited Slide Number: 24
5S Improvement management
3S - Shine Equipment
Example: Water Recycling plant

25. Sundaram-Clayton Limited Slide Number: 25
5S Improvement management
3S - Shine Equipment-Benefits
 Facilitates preventive measures
 Reduces downtime
 Increases flow of equipment effectiveness
 Improves productivity
 Reduces cost

26. Sundaram-Clayton Limited Slide Number: 26
5S Improvement management
4S - Search time elimination
 Transparent storage systems with nomenclature/coding
 Well established visual controls
 Maximum 2 minute for part/document retrieval
 Set up time reduction
 Tool change time reduction

27. Sundaram-Clayton Limited Slide Number: 27
5S Improvement management
4S - Search time elimination-Examples
 Open filing system
 Transparent storage cupboards
 Tool cupboards in shop floor
 Fixture stand in the shop floor
 Color codification for electrical lines, water lines, air lines etc
 Live documents in filing and not records
 Parts identification, fixture identification in the shop floor

28. Sundaram-Clayton Limited Slide Number: 28
5S Improvement management
4S - Search time elimination
Example: Open filing system – Quick retrieval

29. Sundaram-Clayton Limited Slide Number: 29
5S Improvement management
4S - Search time elimination
Example: Transparent storage cupboards

30. Sundaram-Clayton Limited Slide Number: 30
5S Improvement management
4S - Search time elimination
Example: Tool cupboards in shop floor

31. Sundaram-Clayton Limited Slide Number: 31
5S Improvement management
4S - Search time elimination
Example: Fixture stand in shop floor

32. Sundaram-Clayton Limited Slide Number: 32
5S Improvement management
4S - Search time elimination-Benefits
Search time reduced to less than 2 minutes
 Increase in productivity
 Cost reduction
 Eliminates Non Value added (NVA) activities
 Reduces mental agony

33. Sundaram-Clayton Limited Slide Number: 33
5S Improvement management
5S - Set standards, Practice &Discipline
 Standardizing the 4S practices
 Continuous audit and revision of standards
 Training of concerned in the revised standards
 Abolishing unwanted standards

34. Sundaram-Clayton Limited Slide Number: 34
5S Improvement management
5S-Set standard,Practice and Discipline-Examples
 Operation Standards ,Limit samples,Quality Control
Process Charts etc
 Horizontal deployment of standards
 Quality system manual
 Gauge calibration standards
 Recipe standard for cooking in canteen

35. Sundaram-Clayton Limited Slide Number: 35
5S Improvement management
Process of holding gains

36. Sundaram-Clayton Limited Slide Number: 36
5S Improvement management
Process of holding gains
 Daily monitoring through audit scores
 Improving ownership by allocating areas
 Using red tag campaigns
 Communicating visually through fixed point photographs
 Structured communication
 Continuous training of all employees
 Periodic audits at all levels

37. Sundaram-Clayton Limited Slide Number: 37
5S Improvement management
Process of holding gains
 Motivating through recognition
 Encouraging house-keeping projects through Total Employee
Involvement (TEI)

38. Sundaram-Clayton Limited Slide Number: 38
5S Improvement management
Improving ownership by allocating areas

39. Sundaram-Clayton Limited Slide Number: 39
5S Improvement management
Using red tag campaigns

40. Sundaram-Clayton Limited Slide Number: 40
5S Improvement management
Structured communication
 Reviews
 Sunrise meetings
 PDCA meetings for daily management
 In-house journal

41. Sundaram-Clayton Limited Slide Number: 41
5S Improvement management
Results of 5S Management

42. Sundaram-Clayton Limited Slide Number: 42
5S Improvement management
Results of 5S Management
5S management helps to achieve:
 Reduction in warranty claims
 Reduction in assembly rework in-house
 Improvement in inventory turn ratio
 Reduction in customer end line stoppers