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5S Presentation for beginners and professionals for implementation
The document discusses the 5S method developed by Hiroyuki Hirano, aimed at creating an organized and efficient workplace by emphasizing sorting, systematic arrangement, cleaning, standardization, and self-discipline. It highlights the benefits of implementing 5S, including improved safety, productivity, and quality, as well as a reduction in wasted resources and machine breakdowns. The document also outlines the steps for each of the 5S practices and provides guidance on effectively implementing 5S within an organization.
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Introduction to 5S training, its discovery by Hiroyuki Hirano, and objectives of the training.
5S aims to eliminate waste, improve workplace safety and efficiency, requiring minimal resources.
Details of the 5S practices: Sort, Set, Shine, Standardize, Sustain, including steps for each.
5S implementation structure covering audits, patrols, education, and responsibilities.
Examples from Nokia and Benz factories demonstrating successful 5S applications.
Best practices and specific activities associated with each S in the 5S methodology.
Highlights the various benefits of 5S in workplace cleanliness, productivity, and employee morale.
Introduction to red tagging for identifying unnecessary items in 5S.
Visual comparisons showing the impact of 5S implementation on workplace organization and cleanliness.
Encouraging participants to think of 5S in their lives and express interest in certification.
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5S Presentation for beginners and professionals for implementation
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- 2. Thirty years ago,researchers started studying the secret of success of Japanese manufacturing companies. It was Hiroyuki Hirano who developed 5s within his overall approach to production systems. 5s turned out to be the most impressive ‘secret’. Many western managers coming across the approach for the first time found the experience to be enlightening. Hirano provided a structure for improvement programs. He pointed out a series of identifiable steps, each building on its predecessor. Discovery of 5S
- 3. Objectives By the endof the module, the participants will be able to: • Define and understand the importance of the 5s method • Identify and overcome the barriers to productivity • Improve QUALITY of work • Practice efficiency at all times
- 4. Outline Objective 5SFundamentals Check sheet Understanding Before- After Comparison Advantages of 5S Who to implement
- 5. Why do westart 5S The general concept of the 5S is that they are intended to eliminate waste. Working in disorder is neither productive, nor safe. 5S is a simple and practical method to instil a quality culture at the work place. It is relatively easy to undertake, and requires minimal additional resources. The first and small investment made in time and effort pays off in a much bigger manner when the results are realized and maintained. Among the main benefits of implementing 5S are: • the workplace becomes cleaner, safer, well-organized and more pleasant • floor space utilization is improved • workflow becomes smoother and more systematic and non-value added activities are reduced; • time for searching tools, materials and document is minimized; • machine breakdowns are reduced since clean and well-maintained equipment breaks down less frequently and it also becomes easier to diagnose and repair before breakdowns occur, therefore extending equipment life;
- 6. When do westart 5S If we have growing symptoms of these: - Poor state of Machines / Equipment / Tools leading to quality deterioration. - More time is spent in direct and indirect areas by way of searching for Tools / Files / Documents. - Poor house keeping leads to unsafe work place & indirect losses. - Poor material discipline leading to manufacturing delays. - Poor office upkeep leading to delays in transacting with suppliers & customers.
- 7. ABOUT 5S The 5 - S practice is a technique used to establish and maintain quality and safe environment in an organization. The 5 Japanese words are :- 1. Seiri (Sort) – Sort out ( ) 2. Seiton (Set) – Systematic Arrangement ( ) 3. Seiso (Shine) – Spic and Span ( ) 4. Sieketsu (Standardize) -- Standardization ( ) 5. Shitsuke (Sustain) - Self-discipline ( )
- 8. SEIRI – Sortout Segregating the wanted and unwanted items (workplace - )
- 9. 1S- SEIRI/ Sorting The emphasis of Seiri is on stratification management and being able to spot the unwanted and unnecessary before they become problematic Stepsfor Seiri Undertake major cleaning up activities Keep in mind the spirit of waste elimination Develop specific policy & guidelines on the disposal of unwanted things and upkeep of necessary things Devise storage method depending on the priority
- 10. USABLE / WANTEDITEMS 1S- SEIRI/ Sorting
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- 12. •Ensure rational layout of machines, equipment, cabinets •Place frequently-used items at the point of use based on policy •Pre-fix a place foreverything and put everything in its place with pre-determined quantity •Identify useful items with labels/ item name, colour codes and location etc. •Use index for files, records, drawings, etc. •Plan storage with an intent to retrieve easily. •Have visual controls for checking missing items like an inclined stripe for files stored which will indicate a missing file, Shadow graphs for tools storage etc. Seiton in essence can be defined as neatness, having things in the right places or set up so that they are readily available for use, eliminating the need to search. Once everything has a right place so that it’s functionally placed for quality and safety, it can then be deemed that the workplace is neat. While Seiri helps you to decide what items are needed, Seiton helps you to decide the way things are to be placed. Steps for Seiton 2S- SEITON/ Set
- 13. YES NO USABLE ITEMS Isit identified Does it have a storage space Will be using it today Keep it closer to place of use Mark it up / identify Make a space for it Put it away / Stores or Record Room 2S- SEITON/ Set
- 14. Arrangement based onfrequency of use 2S- SEITON/ Set
- 15. SEISO – Spic& Span Clean your workplace thoroughly. (workplace )
- 16. Steps of Seiso •Identify which parts are to be cleaned each shift/ twice daily, daily, weekly, monthly, etc. • Plan for systematic daily or periodic cleaning of all nooks and corners of the zone / whole plant • Ensure cleaning material and cleaning tools are available at an accessible place cleaning • Identify and remove the root causes of such defects/ dust/ dirt 3S- SEISO/ Shine Seiso places emphasis on cleaning so that things are clean; in other words carrying out cleaning as a form of inspection i.e. getting rid of waste, and foreign matter. It is important to note that depending on the circumstance, with higher quality, higher precision and finer processing technologies, even the minute details may have the greatest ramifications, hence the importance to carry out cleaning as a form of inspection
- 17. Seiketsu - Standardization Maintaina standard. ( , 1S,2S,3S |
- 18. • Identify theway different people are doing an activity • Discuss and choose the best way • Make this the standard method once everyone accepts it • Convert this into a written standard, giving a reference Code number • Ensure that everyone does the same work only as per the standard • After accepting it as the standard, review it from time to time and improve it as necessary • Identify the weaknesses in the standard and upgrade them. 3S- SEIKETSU/ Standardize This aspect of the 5S focuses on standardization, making the first three S’s, Seiri, Seiton, and Seiso a constant routine. The emphasis here is on visual management, an important aspect to attain and maintain standardized conditions to enable the individuals always act quickly Steps of Seiketsu
- 19. Shitsuke : Self-discipline Trainpeople to be disciplined ( 5S )
- 20. Steps for Shitsuke •Every employee should know 5S and follow it EVERY DAY from the time of starting to work and repeating it when he closes for the day. • One should keep himself tidy and it will make others to follow • Should do routine activities as per the standards only • One should keep his workplace SPIC & SPAN • Everyone should strictly follow the safety rules • One should always search for abnormalities and solve it 5S- SHITSUKE/ Sustain Shitsuke places emphasis on being able to forge a workplace with good habits and discipline. Demonstrating to others what needs to be done and encouraging practice amongst them. This is mainly a management responsibility.
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- 22. THE SURE WAYFOR ORGANIZATIONAL TRANSFORMATION Education Development of checklists Patrol inspection Monthl y audit Circulate status zone wise Dealing with individual problems Assist in development of standards Divide the area into smaller zones Fix-up the zone-wise responsibility List out activities to be carried out SEIRI, SEITON, SEISO, SEIKETSU, SHITSUKE Prepare standards Carry out 5S daily Follow 5S standards Patrol inspection by Dept. Manager Monthly Audit Assess status, develop counter measures Target for next month Revise 5S standards, if necessary Maintain & improve 5S Adopt some zones Participate in carrying out 5S Patrol inspection Review with Dept Head Provide resources PL A N D O CH EC K AC T TQM/OPEX Office Departments
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- 29. Example- Standardize workArea • Clear, shiny aisle ways • Color coded areas • Slogans, banners • No work-in-process ( WIP ) • One-Piece Flow • Standardized Work Sheets
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- 31. Check sheet- 1S 1.Seiri – Sort out Stratification management and dealing with the causes Typical Activities Location Action by • Throw away things that are not needed • Deal with causes of dirt leaks and noise • Organize cleaning the floors and housecleaning • Treat defects, leakage and breakage • Organize the storage of parts and files • Policy of “One-is-best” - one set of tools/stationery - one page form/memo - one day processing - one stop service for customer - one location file
- 32. 2. Seiton –Systematic Arrangement Functional storage and eliminating the need to look for things Typical Activities Location Action by • Everything has a clearly designated name & place • 30-second retrieval and storage • Filing standards and control • Zoning and placement marks • Eliminate covers and locks • First in, first out arrangement • Neat notice boards (also remove obsolete notices) • Easy-to-read notices (including zoning) • Straight-line and right angle layout • Functional placement for materials, parts, tools etc Check sheet- 2S
- 33. 3. Seiso –Spic & Span Cleaning as inspection and degree of cleanliness • Individual cleaning responsibility assigned • Make cleaning and inspection easier • Regular sparkling cleaning campaigns • Cleaning inspections and correct minor problems • Clean even the places most people do not notice Typical Activities Location Action by Check sheet- 3S
- 34. 4. Seiketsu -Standardization Visual management and 5-S standardization • Transparency ( e.g. glass covers for see-through) • Inspection “OK” marks or labels • Danger zones marked on meters and switches • ‘Danger’ warning signs and marks • Fire extinguisher and ‘Exit’ signs • Directional markings on pipes, gangways etc • Open and shut directional labels on switches etc • Colour-coded pipes Typical Activities Location Action by Check sheet- 4S
- 35. Seiketsu - Standardization... Visualmanagement and 5-S standardization • Foolproofing (Poka-yoke) practices • Responsibility labels • Electrical/telephone wire management • Colour coding - paper, files, containers etc • Prevent noise and vibration • Department/office labels and name plates • Park-like environment (garden office/factory) Typical Activities Location Action by Continued….
- 36. 5. Shitsuke -Discipline Habit formation and a disciplined workplace • All-together cleaning • Do daily physical exercise all together • Practice pick-up components and rubbish • Wear your safety helmet/gloves/shoes etc • Public-space 5-S management • Practice dealing with emergencies • Execute in individual responsibility • Good telephone and communication practices • Design and allow the 5-S manual • Seeing-is-believing: check for 5-S environment Typical Activities Location Action by Check sheet- 5S
- 37. Dept. Asembly Date Dept.1 Assignedarea Entered by: Page No. No. Process and checkpoint Sort Set in order Shine Total Previous total 1 Work at Line A, Process 1 8 6 2 " 8 6 3 " 6 5 4 " 7 7 5 " 10 6 6 " 12 8 7 Average and total for Line A 51 38 Standardization Level Checklist 1111 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 1 532 4 2.6 2.8 2.8 Standardization Level Cheek Sheet
- 38. Benefits of practicing5S • the workplace becomes cleaner, safer, well-organized and more pleasant • floor space utilization is improved • workflow becomes smoother and more systematic and non-value added activities are reduced; • time for searching tools, materials and document is minimized; • machine breakdowns are reduced since clean and well-maintained equipment breaks down less frequently and it also becomes easier to diagnose and repair before breakdowns occur, therefore extending equipment life; • errors are minimized leading to making defect-free products; • consumables and material wastage are minimized; • the morale and satisfaction of employees improves; and • the productivity of the organization improves together with the quality of products and services. BENIFITS
- 39. Identify Red Tag? PIC-1 PIC-2
- 40. Identify Red Tag? PIC-3 PIC-4
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- 44. BEFORE- AFTER Comparison Before5S After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)
- 45. BEFORE- AFTER Comparison 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
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- 52. Now Think … Thinkabout some 5S example, made real life simpler? How you will contribute ? Who wants to be Certified by us ?