5S Training materials at ISPAT

1. PREPARED BY : DEEPAK SAHOO
DOC. NO. : BAL/TPM/TR/5S/1005
5S
Awareness
Training Program
BALASORE ALLOYS LTD.
Presented by : Deepak Sahoo

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Index
1)5S Overview
2)Waste and Benefit’s of 5S
3)1S - SEIRI / Sort
4)2S – SEITON / Set
5)3S – SEISO / Shine
6)4S – SEIKETSU / Standardize
7)Visual Control
8)5S – SHITSUKE / Sustain
9)Before and after Photographs
10)Feedback and Comments
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5S - A new way of thinking for change ?
Think of the rocks and boulders as barriers because they slow down the water flow. 5S is the first step to eliminate these barriers.

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What is Waste ?
 Waste is anything that the customer does not look for or the customer does not wish to pay for.
 All the non value adding activities are WASTE !
 Non value adding activities are those , which do not contribute to the functional value of the end product.
Anything other than the Minimum amount of equipment, Material, Parts and working time absolutely essential to Production.

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Ice berg analogy: > 90 % waste invisible
Waste is like a Eagle / Grave yard
Visible waste
Invisible waste

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Observe this slide carefully.
Current Stage
Transformation
Future Stage

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What is 5S?
5S is a systematic development process for creating a clean, safe and efficient workplace.
Japanese
English
Meaning
1S
SEIRI
SORT
Clear
2S
SEITON
SET
Orderliness
3S
SEISO
SHINE
Clean and make it dust free
4S
SEIKETSU
STANDARDIZE
Define & Refine
5S
SHIITSUKE
SUSTAIN
Adherence

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Steps of 5S.
1. Sort - Clear
2. Set - Orderliness
3. Shine – Clean and make it dust free
4. Standardize – Define & Refine
5. Sustain – Adherence

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Benefit’s of 5S :-
SAFETY
EFFICIENCY
QUALITY
ELIMINATING BREAKDOWNS
5 S
 5 S LEADS TO CLEAN & WELL ORGANIZED WORKPLACE
 5 S LEADS TO BETTER SAFETY
 5 S LEADS TO HIGHER EFFICIENCY
 5 S LEADS TO BETTER QUALITY
 5 S LEADS TO REDUCTION OF MACHINE BREAKDOWNS

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Don’t live with temp. arrangements.

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Step by step implementation
NOTE : Before implementing SORT, please take photographs of the various locations and make a note of the date.
The photographs “BEFORE” to be displayed
at that location.

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Step by step implementation
UNIT :- Formaldehyde Plant Unit -4
Doc. No :- TPM/5S/B/A2/1004
Location :- Chemical Lab near SW corner
Responsible Person :- Mr. R. Kulkarni
BEFORE 5S – (20.10.2010)
AFTER 5S – (DD.MM.YYYY)
?
COMMENTS :- The searching time was more. Chemical storage was not proper.
COMMENTS :-

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1S : SORT
Step 1
•Look around your area and make a List of all Items prevailing to that area
Step 2
•Ask your team and Yourself “ Everything here is required or not” means decide which are necessary and Unnecessary.
Step 3
•Sort out Unnecessary and Keep them in “RED TAG AREA”
Step 4
•Decide What to be done with Red Tag Area Items
Step 5
•Make a schedule for 1S.

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1S : SORT
Meaning
Distinguish between necessary and unnecessary items and remove all items from the workplace that are not needed for work place.(parts, tools, equipment, etc).
Activity
Establish a criteria for eliminating unwanted items.
Eliminate unwanted items either by disposing or by relocating.
Uses RED Tag.
Success
Area Save and getting spacious work place.
Reduce the Minor accident and better Spare part management.

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SORT : How we will approach ?
Decide what you need and the
frequency of the tools use.
Remove unnecessary clutter tools,
gauges, materials etc.
Remove items which are broken,
unusable or only occasionally used.
Use Red Tag for disposal.

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SORT : Examples

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2S : SET
Meaning
To determine type of storage and layout that will ensure easy accessibility for everyone.
Activity
Functional storage.
Shadow box, Marking.
30 Second rule
Creating place for everything and putting everything in its place.
Success
Time saved in searching
Time saved in material handling & Reduce MTTR.

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2S : SET
Step 1
•Understand the frequency of usage of Necessary Item.
Step 2
•Give a Place to all Necessary Items according to step 1.
Step 3
•Give a Name and Code to every Place and Item.
Step 4
•Use Separator Line to maintain discipline .
Step 5
•Establish as many as visuals so that item can easily be tracked and placed.
Step 6
•Make sure no one can violet the discipline.

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S ET : How we will approach ?
 SET means we arrange items so they are easy to use, and
labeling them so they are easy to find and put away.
 It also means operating efficiency.
 Compile LITMUS TEST.
LITMUS TEST
It is also known as 30 SECOND
RULE. One must locate the items
within 30 seconds.

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SET : Game :: Observe it Carefully.
There are 16 tools.

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S ET : Game
There are 14 tools : which 2 tools missing ?

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S ET Game.

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SET : Game
Paint brush 1Paint brush 2Drill M/C 1Measuring tapeSpanner 2Cutting wheelHammerTorchSawPlierDrill M/C 2Spanner 1ViceScrew driverPlumber spannerHorticulture tool

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SET : Game
Paint brush 1Paint brush 2Drill M/C 1Measuring tapeSpanner 2Cutting wheelHammerTorchSawPlierDrill M/C 2Spanner 1ViceScrew driverPlumber spannerHorticulture tool

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SET : Before & After

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SET : Before & After

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2S : SHINE
Clean to Inspect, Inspect to Detect, Detect to Correct Correct to Improve.
Seiso (Shining)

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2S : SHINE
Meaning
Cleaning trash, filth, dust and other foreign matter.
Identify and eliminate causes of dirt; find out the root cause.
Activity
Devote 5 minutes everyday for cleaning your work area
Keep workplace spotlessly clean
Inspection while cleaning
Finding minor problems with cleaning inspection
Success
Reduction in machine down time
Reduction in no. of accidents

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2S : SHINE
Step 1
•Establish a Cleaning Schedule.
Step 2
•Establish the Cleaning Tools.
Step 3
•Establish the Cleaning Methods.
Step 4
•Track the abnormalities during Cleaning.
Step 5
•Strictly adhere the Schedule.
Step 6
•After two months of Practising make the Cleaning Standard.

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S HINE : How we will Approach ?
SHINE means we sweep floors, scrub machines,
apply a fresh coat of paint, and then we keep
it that way.
Create a spotless workplace.
When you Sweep and Shine an area, inspect
machinery, equipment, and working conditions.
Devote 5 minutes everyday for cleaning
your work area
Find out the source of contamination.
Conduct root cause analysis to get the
sources and arrest.

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4S : Standardize
Meaning
Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure).
Activity
Innovative visual management.
CLTI (Cleaning, Lubrication, Tightening & Inspection) Checklist .
Color coding
Early detection of problem and early action
Success
Increase in 5S indicator & better fault finding.
Make things easier for operator.

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4S : Standardize
Step 1
•Standardise 1S, 2S and 3S.
Step 2
•Establish SOPs for 1S , 2S and 3S.
Step 3
•Develop and Establish 5S Audits and frequency.
Step 4
•Establishment of Reward system for enhancing Morale.

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Visual Control
Visual Control refers to the System of Exposing Deterioration or Displaying the Status, just by making it Visible.
Salient features:
No need to Ask, Think or Walk to get the status
 Deviation should Attract the Eye at a glance
 Should be Unambiguous / Universal
HER
HIS

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Visual Control

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V isual Control
Shadow boards
ON
SPZ 1600

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Visual Management

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Visual Management

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Visual Control in File Management
FILES NOT IN ORDER

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Visual control : Examples in office

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5S : Sustain
Meaning
Every one sticks to the rule and makes it a habit.
Activity
Participation of everyone in developing good habits.
Regular audits and aiming for higher level.
5S Training, 5S Competition / evaluation, 5S Posters , Literature etc.
Success
High employee morale Indicator.
Involvement of all people.

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5S : Sustain
Step 1
•Ensure no one can violet Step 4.
Step 2
•Establishment of Penalty like system for not following 4S.
Step 3
•Establish the Score Board .
Step 4
•Give Regular mentoring/Coaching and Training.

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Photographs for improvement
UNIT :- Formaldehyde Plant Unit -4
Doc. No :- TPM/5S/B/A2/1004
Location :- Chemical Lab near SW corner
Responsible Person :- Mr. R. Kulkarni
BEFORE 5S – (20.10.2010)
AFTER 5S – (28.10.2010)
COMMENTS :- The searching time was more. Chemical storage was not proper.
COMMENTS :- Chemical searching time reduced to 25 seconds. All chemicals are properly marked. 5S Score – 85.7%.

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Before and After photographs

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Before and After photographs

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5S Review
 What is 5S ?
 Steps of 5S ?
 What we do during SORT process ?
 What is LITMUS test ?
 What are the benefits of 5S ?
 What is visual control ?
 Difference between STANDARDIZATION & SET ?
 Why it is called 5S not 6S or 3S ?
 Why we take photographs before 5S implementation ?
 5S : All steps ?

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