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8721675-An-introduction-to-5S-activities (1).ppt
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- 3. 1. 5S Principles Elimination of waste Elimination of waste Every body is involved, Every body is involved, Co-operative effort Co-operative effort Attack root cause Attack root cause Human being is fallible Human being is fallible
- 4. 2. Objectives Improvehousekeeping Improve housekeeping Make every individual responsible Make every individual responsible for housekeeping for housekeeping Beautify by simple means Beautify by simple means Productivity improvement by Productivity improvement by saving time, space etc. saving time, space etc.
- 5. 3. 5S’s • Seiri Seiri- Sorting - Sorting • Seiton Seiton - Systematic arrangement - Systematic arrangement • Seiso Seiso - Cleaning - Cleaning Inspection while cleaning Inspection while cleaning • Seiketsu Seiketsu - Standardization - Standardization • Shitsuke Shitsuke - Self Discipline - Self Discipline
- 6. 5S If we donot do 5S, we can’t do any other work efficiently. They are features which are common to all places and are the indicators of how well an organization is functioning.
- 7. COMMON MIND SETS… Itsan additional burden. Too busy to do 5S activities. Why clean it? It will get dirty again We cannot change the existing setup. More work pressure – No time for these things 5S means cleaning up the desk
- 8. SEIRI = SEIRI =Sorting – Just in Case to Sorting – Just in Case to “Just-in-Time” “Just-in-Time” Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items Activity: Establish a criteria for eliminating unwanted items. - Eliminate unwanted items either by disposing them or by relocating them. Success Area saved or percentage of space available Indicator
- 9. SEIRI = SEIRI =Sorting – Fight with Sorting – Fight with habits habits
- 10. SEIRI = SEIRI =Sorting 3 Categories Sorting 3 Categories √ - Item Required X X – – Item Not Required Item Not Required ? ?– – Undecided Undecided Move to Red Tag Holding Area Move to Red Tag Holding Area
- 11. 1. Item isnot needed 2. Item is needed however quantity in stock is more than what is needed for consumption in near future 3. Item is needed but once in a blue-moon 4. Contingency Parts Critically decide the quantity of contingency parts to be retained and criteria for such parts Seiri = Sorting What is unnecessary
- 12. Frequency of useStorage Method *Things you have not used in the past one year Throw them out *Things you have used once in the last 6-12 months Store at distance OR Keep in store LOW *Things you have used only once in the last 2-6 months Store it in central place in your zone *Things used more than once a month Store it in central place in your zone A V E R A G E HIGH *Things used once a week Store near the workplace *Things used daily or hourly Store near the workplace Organization
- 13. Seiri = SortingIdentifying unnecessary 1. Parts & Work in Process (WIP) • Things fallen back behind the machine or rolled under it • Broken / some items inside the machine • Things under the racks/ platform • Extra WIP • Stock of rejected items • Items accumulated over period for rework • Material awaiting disposal decision • Material brought for some trial, still lying even after trial • Small qty of material no longer in use Contd..
- 14. Seiri = SortingIdentifying unnecessary 2. Tools, Toolings, Measuring devices • Old jigs, tools not in use are lying • Modified tools, tooling for trial, are lying after trial • Worn out items like bushes, liners, toggles etc. lying • Broken tools, bits, etc. may be lying • Measuring equipment not required for the operation being performed, is lying 3. Contingency Parts • Many times storage place for contingency parts become a last refuge for broken parts, surplus items and things nobody is likely to use Contd..
- 15. Seiri = SortingIdentifying unnecessary 4. Shelves and Lockers • Shelves and lockers tends to collect things that nobody ever uses, like surplus, broken items, used tea-cups etc. 5. Passages and Corners •WIP material waiting for decision or dispatch • Dust, material not required seem to gather in corner 6. Besides Pillars and under the stairs • These places tends to collect junk, spittoon etc. 7. Walls and Bulletin Boards • Old out dated notices which have lost their relevance • Posters or bulletins on wall • Dust, remains of torn notices, cell tape pieces Contd..
- 16. Seiri = SortingIdentifying unnecessary 8.Floor, Pits, Partitions • Defective parts • Protection caps, shoe covers • Packing material, stickers, barcodes, cut-leads • Hardware items, small items, runners, plastic granules • Even tools, tooling Items dropped on the floor are never picked 9.Computer Hard Disk • Many unwanted, outdated, temporary files pile up •Old dated mails still remaining in inbox and sent items •Deleted mails not being purged when closed •Recycle bin not emptied
- 17. Seiri = SortingTAGGING TAG No ______________ Date _________ ITEM NAME________________ QTY ______ Tag Created By: _________________________________ Reason: ________________________________________ _______________________________________________ _______________________________________________ Decision Date: ___________ Decision By: __________ To Scrap To Reuse after Salvage To Dispose G IC R E D T A G
- 18. Seiri = SortingImprovement methods 1. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system eg. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for system eg. How to perform Seiri (sorting) 3. Check List A check sheet is used to decide what sort of main system and sub system are necessary.
- 19. PLANT: No. PARAMETERS EXCE.GOOD AVG. BAD POOR POINTS 5 4 3 2 1 1 Is there any UNWANTED item present in area 2 Is there any item more than required 3 Is there any item on different location 4 Is there proper Red Tag Area identified 5 Is the list of all items in Red Tag Area available 6 Is there any classification done for Wanted items 7 Is there any item not used for more than a year 8 Is there criteria present to eliminate unnecessary items 9 Is there any unwanted dirt/dust present 10 Is there any leakage present (Air, Water, Oil or Material) 11 Is there any defective item present or Unsafe item in the area 12 Is there any spilled item on the floor 13 Are all Equipments, Jigs & Machines working OK 14 Is there minimum 20 % storage free space available 15 Are People working in the area aware about 1 - S OVERALL SCORE NOTE: MINIMUM 75 % REQUIRED FOR NEXT STEP AUDIT REMARKS: 1 - S CHECKLIST - SHOPFLOOR DATE: AREA: PERSON RESPONSIBLE:
- 20. Seiri = SortingDealing with papers How to reduce papers on your table ? 1. Make a single pile of papers 2. Go through them and sort in following categories a) Immediate action b) Low priority c) Pending d) Reading material e) For information
- 21. Seiri = SortingDealing with papers How to reduce papers on your table ? 4 D Principle 4 D Principle DO DELEGATE DELAY DUMP
- 22. SEITION = SEITION =Systematic Arrangement Systematic Arrangement Meaning To determine type of storage and layout that will ensure easy accessibility for everyone . Activity - Functional storage - Creating place for everything and putting everything in its place Success - Time saved in searching (30 sec to locate an item) Indicator - Time saved in material handling
- 23. SEITION = SEITION =Systematic Arrangement Systematic Arrangement In short, SEITION means PEEP Place for Everything & Everything in its place
- 24. Seiton = SystematicArrangement How to achieve Systematic Arrangement ? • Decide where things belong Decide where things belong • Decide how things should be put away Decide how things should be put away • Obey the Put away rules Obey the Put away rules
- 25. Seiton = SystematicArrangement How to achieve Systematic Arrangement ? • Decide where things belong - - Standardize Nomenclature - Determine an analytical method of storage • Decide how things should be put away - - Name & locations to everything. Label both item and location - Store material functionally - Prevent mistakes with coding by shapes & color contd.. contd..
- 26. Seiton = SystematicArrangement How to achieve Systematic Arrangement ? • Decide how things should be put away - - Follow first in first out rule - If two identical items are to be located, then stor them separately, color code them. • Obey the rules - - Put the things back to their location after their use
- 27. Seiton = SystematicArrangement USE : USE : 1 ) Signboards 1 ) Signboards 2) Color codes 2) Color codes 3) Outline markings 3) Outline markings 4) Labels 4) Labels
- 28. Seiton = SystematicArrangement Functional Functional Storage Storage
- 29. Seiton = SystematicArrangement Usage Frequency • Store frequently used material near the workplace and less frequently at some distance Weight & Shape of the Material • Heavy material should be stored at lower levels/layers Place directly on the material handling device for ease of handling Functional Storage
- 30. Seiton = SystematicArrangement Category • Same category of material may be stored in one location. Eg. Fasteners, Seals , resistors Operation Wise • All items required for an operation may be stored in one location. Eg. Allen key, spanner etc hand tools required for setting m/c Functional Storage
- 31. Seiton = SystematicArrangement • Outlining and Placement Marks - - Mark boundaries of dept., aisles, Machines - Follow straight line, right angle rule - Nothing shall be kept outside the boundaries • Stands and shelves - - Keep only required number of stands and shelves - Standardize height, size - Provide casters where necessary so that it can be moved
- 32. Seiton = SystematicArrangement • Wires and Ducts - - Color code - When there are multiple connections - bundle the wires, label them and make sure that they are in straight line /right angle and firmly anchored • Machine-tools & Tools - - Put the tools in the order you need them - Location of the tool should be such that it can be put away with one hand - Try to eliminate some hand tools by permanently attaching it to the bolt head
- 33. Seiton = SystematicArrangement Blades, Dies, Other important consumables - - Store them in the protected place - Maintain these things regularly by applying rust preventive, oiling etc. • WIP- Work In Process - - Designate a place for each component/part - Decide on how much quantity to be stored - Ensure that there is no damage to good part during transit, they do not get rusty and they are not mislabeled
- 34. Seiton = SystematicArrangement • Oils & Lubricants - - Reduce number of oils used (Standardize) - Color code for oil - Safety aspects - fire prevention, pollution, leak, spillage • Instrumentation & Measuring Devices - - Label them, show direction of flow
- 35. SEISO = SEISO =Cleaning Cleaning Meaning Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of Inspection Activity - Keep workplace spotlessly clean - Inspection while cleaning - Finding minor problems with cleaning inspection Success - Reduction in machine down time Indicator - Reduction in no. of accidents
- 36. Seiso = Cleaning •Here cleaning means more than just keeping Here cleaning means more than just keeping things clean. Cleaning should be viewed as a things clean. Cleaning should be viewed as a form of Visual Inspection form of Visual Inspection • Preventive measures should be taken to tackle Preventive measures should be taken to tackle problems of dust, grim, burrs, leakage etc. problems of dust, grim, burrs, leakage etc. Root cause of the problem should be identified Root cause of the problem should be identified and it should be eliminated and it should be eliminated
- 37. Seiso = Cleaning VariousMinor Defects Various Minor Defects = Trash = Dirt =Knocking = Loose parts = Leaks =Scattering =Skips =Curvature =Abrasion =Rust =Scratches =Eccentricity =Lurching =Abnormal =Vibration Movements =Abnormal =Heat =Abnormal Sounds smells =Faded color =Hisses - Cracks
- 38. Seiso = Cleaning 5Minutes Every day for cleaning 5 Minutes Every day for cleaning • Devote 5 minutes everyday for cleaning your Devote 5 minutes everyday for cleaning your work area work area • Participation of everyone is required Participation of everyone is required • Attack hard to clean places regularly Attack hard to clean places regularly
- 39. Seiso = Cleaning Cleaning-Inspectionpoints for most Cleaning-Inspection points for most equipment equipment Cleaning Grime, clogging, dust balls, rust, leakage etc. Oils No oil, Low oil, leakage, filter clogging, dirty oil, dirty or bent oil lines, clogged drainage, oil spillage, worn& torn ports etc.
- 40. Seiso = Cleaning Cleaning-Inspectionpoints for most Cleaning-Inspection points for most equipment equipment Tightening Loose bolts, welding detachment, loose parts, vibration or bumping noise, friction Heat Oil tanks, motors, heater, axles, control panels, washing/ cleaning water, bearing, wiring etc.
- 41. Seiso = Cleaning Cleaning-Inspectionpoints for most Cleaning-Inspection points for most equipment equipment Breakage, Cracks Breakage, cracks, dent on sliding parts, handle has come off, broken switches, wire joints come off, wires are broken or crack, crack dial of various pre. gauges, meters etc.
- 42. Seiso = Cleaning Functionwise Cleaning check list of Function wise Cleaning check list of equipment equipment Pneumatics Hydraulics Compressed Air lines, air valves, connections, meters, filters, reservoirs etc. Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc.
- 43. Seiso = Cleaning Functionwise Cleaning check list of Function wise Cleaning check list of equipment equipment Mech & Power Train Electrical Motor fan, fan belt, couplings, Joints, pulleys, chains, pump bearings etc. Control panel, lamps, light, switch, sensors, wiring, ducts, fuses etc.
- 44. Seiso = Cleaning Functionwise Cleaning check list of Function wise Cleaning check list of equipment equipment Toolings Equipment Specific Tools, fixtures, gauges, dies, measuring instruments, etc. Furnaces, rollers, chutes, CNC machines, etc.
- 45. SEIKETSU = SEIKETSU =Standardization Standardization Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure) Activity - Innovative visual management - Color coding - Early detection of problem and early action Success Increase in 5S indicator Indicator
- 46. SEIKETSU = SEIKETSU =Standardization Standardization Tools used for analysis : MTTR MTBF OEE
- 47. Seiketsu = Standardization Seiketsu= Standardization • Regularizing 5S activities so that abnormalities are revealed •Make it easy for everyone to identify the state of normal or abnormal condition • For maintaining previous 3S, deploy visual management
- 48. Seiketsu = Standardization Seiketsu= Standardization • It has been estimated by scientific study that 60% of all human activities starts with sight • 5S is easy to do once.It is consistency that is difficult. That is why Visual Management is so important, so that everybody will know that there is some problem. Visual Management Visual Management
- 49. Seiketsu = Standardization Seiketsu= Standardization What visual control communicates ? What visual control communicates ? It grabs one or more of our senses in order to • Alert us to an abnormality • Help us recover quickly • Promote adherence and prevention • Enable successful self management
- 50. Seiketsu = Standardization Seiketsu= Standardization Some methods for visual communication Some methods for visual communication Color coding Use of Labels Danger alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators
- 51. Seiketsu = Standardization Seiketsu= Standardization Some methods for visual communication Some methods for visual communication Labels Labels Precision management labels Inspection labels Temperature labels Responsibility photos
- 52. Seiketsu = Standardization Seiketsu= Standardization Points to remember in making visual c Points to remember in making visual c control tools control tools 1. Make them easy to see from distance 2. Put the display on the things 3. Everyone can tell what is right and what is wrong 4. Anybody can follow them and make necessary corrections easily 5. Work place should look brighter & orderly
- 53. Seiketsu = Standardization Seiketsu= Standardization Some everyday visual management Some everyday visual management examples examples Traffic signal Zebra crossing In car - Petrol indicator - Speed indicator Direction arrows Electric danger sign Toilet
- 54. Seiketsu = Standardization Seiketsu= Standardization Some visual communication signs Some visual communication signs
- 55. SHITSUKE = SHITSUKE =Self Discipline Self Discipline 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 Success High employee morale Indicator Involvement of all people
- 56. SHITSUKE = SHITSUKE =Self Discipline Self Discipline Activities : 5S Committee 5S Training 5S Competition / evaluation 5S Month Posters , Literature etc.
- 57. Shitsuke = SelfDiscipline Shitsuke = Self Discipline We need everyone to maintain 5S We need everyone to maintain 5S guidelines. guidelines. To maintain DISCIPLINE, we need To maintain DISCIPLINE, we need to practice and repeat until it to practice and repeat until it becomes a way of life. becomes a way of life. Discipline is the Core of 5S Discipline is the Core of 5S
- 58. Shitsuke = SelfDiscipline Shitsuke = Self Discipline Discipline means making a steady Discipline means making a steady habit of properly maintaining habit of properly maintaining correct procedure correct procedure. Time and effort involved in Time and effort involved in establishing proper arrangement establishing proper arrangement and orderliness will be in vain if and orderliness will be in vain if we do not have discipline to we do not have discipline to maintain it. maintain it.
- 59. Shitsuke = SelfDiscipline Shitsuke = Self Discipline Pledge Pledge It shall be my constant effort to It shall be my constant effort to maintain my workplace in good maintain my workplace in good order by order by Assigning a place for everything Assigning a place for everything & keeping everything in its place & keeping everything in its place Sorting out unwanted material Sorting out unwanted material periodically & discarding them periodically & discarding them Keeping my work area neat & Keeping my work area neat & clean everyday clean everyday
- 60. Machine building Bay Machinebuilding Bay
- 61. Heat Treatment Area HeatTreatment Area
- 62. Heat Treatment Area HeatTreatment Area
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- 64. End of the presentation& Beginning of 5S activities….
Editor's Notes
- #1 5S is a process set down by the Japanese to maintain house-keeping. This is the DNA for any developmental program. Without implementing 5S, one cannot progress in any developmental activity. 5S helps us to keep the environment clean, helps us to identify waste, excess, non-moving that are unhealthy to an organization. A kitchen in every household is the best example for 5S maintenance. One does not need to go for plant tours instead observe your kitchen. At the least, your spouse would be happy enough that you are paying attention to her. 5S is not one day activity or a flavor of the month. It is a continuous process and one should keep on doing it day-in and day-out.
- #2 This graph indicates the quality improvements do increase dramatically if 5S is followed. Basically, Indians do possess the lacuna of untidyness and we live with it. If we start implementing 5S, it will not take years for us to catch the leaders.
- #3 Our human body is the right example of processing the elimination of waste. Imagine a day without being making a visit to toilet. What will be our status? Similarly, any waste that is generated has to be purged or removed. This is not the duty of any single person but everyone. However, how long one has to keep on purging the waste. Of course one gets tired of this activity. If you do not want to get bored, then find out the root cause for the waste generation and then attack it. Infallible means “sure to succeed”. To Err is human, and to prevent him erring repeatedly, 5S is essential.
- #4 It is human nature for every human being to project himself presentable or beautiful. So, why not the place we work in? Don’t we keep our living rooms presentable? Then why cant we do the same to our workplace? In house, every family member does his part to keep it clean and here also we follow the same principle. We do not need an interior decorator to beautify the shop but simple things would do. Mind it “winners do not do different things but do things differently”. Obviously, by keeping our house clean, we get indirect benefits in terms of time saving etc.,
- #5 What makes 5S? The 5 Japanese words starting with letter S and its equivalent English Words that relate to the 5S activities.
- #6 One cannot read one’s mind but can make out an impression by seeing the appearance. Perception is more than reality. If we do not present ourselves well, we cannot sell ourselves. If we do not imbibe the discipline of cleanliness, even our spouses would leave us for good.
- #7 One cannot read one’s mind but can make out an impression by seeing the appearance. Perception is more than reality. If we do not present ourselves well, we cannot sell ourselves. If we do not imbibe the discipline of cleanliness, even our spouses would leave us for good.