The document discusses the 5S methodology for performance excellence and continuous improvement. It describes the 5S principles as sort, set in order, shine, standardize, and sustain. When implemented, 5S helps eliminate waste, improve organization and visual control of the workplace, and standardize processes to maintain improvements and control critical parameters. Examples show how 5S can organize storage, clean work areas, and establish standard processes.

1. A STRATEGY FOR PERFORMANCE EXCELLENCE 5s

2. What is 5S ? An essential step required for Waste Elimination An integral step in Kaizen A required element to achieve Lean-site Manufacturing. Systematic Organization “ Seiri” Orderliness “ Seiton” Cleanliness “ Seiso” Cleanup “ Seiketsu” Cleanup “ Seiketsu” Standardization/Perseverance “ Shitsuke” 5s

3. 5S Performance Excellence Model Systematic-Systematic Organization Scrubbing clean Self-Discipline- Control Customer Expectations Sorting Visual Placement Standardizing Control Improved Quality Improved Safety Reduced costs Consistent Deliveries Improved Product/ Service Options 5s

4. Improvement (Kaizen) Principles Get rid of all old (false) assumptions. Don't look for excuses, look for ways to make it happen . . Don't worry about being perfect - even if you only get it half right “start NOW”! It does not cost money to do KAIZEN or 5S If something is wrong “Fix it Here &NOW”. Good ideas flow when the going gets tough. Ask "WHY" five times - get to the root cause. Look for wisdom from Ten people rather than one. Never stop doing KAIZEN & Sustain 5S

5. Respiratory System 1 ‘S’ – Our respiratory system sorts oxygen and other gases. And exhales other gases which are unwanted for our body 1 ‘ S’ - SEIRI

6. 2 ‘S’ – In our body there is a fixed place for every organ. 2 ‘ S’ - SEITON

7. 3 ‘ S’ - SEISO 3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc

8. 4 ‘S’ – In every human being the structure of fingers are same I.e Standardised. If it is not so, then we call it is abnormal. 4 ‘ S’ - SEIKETSU

9. 5 ‘S’ – Every human body has its standard process which they maintain. 5 ‘ S’ - SHITSUKE

10. 1 ‘S’ Seiri Sort for . . . Not Needed at All Needed but not Now Needed but not here Needed but not so much Quantity 1 ‘ S’ WANTED UNWANTED

11. Example: Jigs & tools Anybody Immediately Can See Can take out Can return Where – Fix the position What – Fix the item How Many – Fix the Qty

12. Clean Procedure: Decide what to clean Decide who is in charge of each cleaning Decide on cleaning method Prepare cleaning tools and equipment Implement cleaning

13. WHAT TO DO STANDARDISATION . . . Workstation layout,work area layout Work in progress Sequence of work Material & tools used Machine & their process parameters Quality parameters, methods of measurement & reporting methods 5 W’s and 1 H

14. ENSURE . . . Procedure & Work Instruction are correct. Standard are expressed in specific. Visual Aids are used. Train at all levels. Work ethics for effective management. Transparent & Discipline work culture.

15. Why 5S To eliminate the wastes that result from “ uncontrolled” processes. To gain control on equipment, material & inventory placement and position. Apply Control Techniques to Eliminate Erosion of Improvements. Standardize Improvements for Maintenance of Critical Process Parameters. Look Familiar ? 5s

16. Overproduction Delays (waiting time) Transportation Process Inventories Motions Defective products Untapped Resources Mis-used Resources 9 Wastes The Nine types of wastes.

17. Overproduction ______________________________ Delays (waiting time)__________________________ Transportation _______________________________ Process_____________________________________ Inventories__________________________________ Motions ____________________________________ Defective products ____________________________ Untapped Resources __________________________ Mis-used Resources ___________________________ 9 Wastes Give an example of each type of waste. The Nine types of wastes Think Break

18. Stop accidents through good housekeeping Tripping over loose objects on floors, stairs and platforms. • Articles dropping from above Slipping on greasy, wet or dirty surfaces. Striking against projecting, poorly stacked, or mis- placed material • Tearing the hands or other parts of the body on projecting nails, wire, steel strapping on bales or crates, etc. Typical examples of poor housekeeping that lead to these accidents are: • Excessive material, waste or chips in the working area. • Congested aisles. • Tools left on machines. • Waste Containers overflowing. • Lockers and workrooms in disorder. • Acids in open containers. • Broken glass. • Electric leads or air lines across aisles. • Dirty light fittings, windows and skylights.

19. We must maintain following : Gangways are always maintained clean and clear Everything has place and is kept there only Waste disposal is ensured time to time and area is kept clean Material layout IN & OUT is proper with adequate storage facility. Frequency , Quantity, limits, container size , location for each material is as per norms. Floor is clean and is without oil, grease , dust or dirt always. First Aid box is well maintained and is at its place. Fire control equipments are well maintained. TPM schedule / 5S schedule is regularly adhered. WE WILL CARE FOR OUR ITEM WASTE DISPOSAL WE WILL ENSURE NO MATERIAL IS ON THE FLOOR. ( ONLY FOOT ON FLOOR )

20. 2S Audit Check Sheet ii.Documentation i.Seperate Location Procedure - red tag 5 maximum and minimum level of storing? iv) Is storage space properly marked for iii) Have they been properly identified? ii) Condition of items in almirahs and tool boxes i) Do they stock and store at prefixed place? Storage Material 4 c) Rejection b) To be rework a) To be used iii) Is their proper place for materials. ii) Are they having proper identification? i) How parts/work in progress kept? Parts & Material 3 v. No chipping or paint flaking on floors iv. Floors clean iii. No defectives scatter about ii. No trash or parts on floor i. No oil spilled on floor Floor 2 ii. Every Operator knows his "5S" responsibilities. delineated at line level. i. "5S" Responsibilities are clearly Area Management 1 5 4 3 2 1 0 Score Check Points Check Item Sl. No.

21. Some 5S Examples Before 5S After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting )

22. Some evidence of standardized work areas Clear, shiny aisle ways Color coded areas Slogans, banners No work-in-process ( WIP ) One-Piece Flow Standardized Work Sheets

23. 5S Examples - Sort, Set in Order See the difference? 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

24. 5S Examples - Shine 3. Shine - The area is cleaned as the work is performed (best) and\or there is a routine to keep the work area clean.

25. Before shine after shine

26. The Good, Bad and the Ugly First the Bad and the Ugly - Life Without 5S

27. The Good

28. Nice place…! There is no second chance to make the first impression!

29. We must bring to this level. VW assembling plant