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L 1 uc-19 apply 5s procedure
1. APPLY 5S PROCEDURE
BASIC APPAREL PRODUCTION
LEVEL ONE
Unit of Competence 19
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2. KAIZEN
Is a Japanese word which means…
- Change for better.
- quest for continuous improvement.
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3. TOOLS / METHODTO MAKE KAIZEN WORK:
1. Human Resources(HR) emphasis
2. Three(3) balloons to success
3. Three(3) M for doing a job.
4. Five(5) S strategy
5. Five (5) fields of training
6. Seven(7) types of waste
7. KAIZEN continuous improvement board.
IMPORTANT:
“ EVERYONE SHOULD BE RESPONSIBLE AND
EVERYBODY SHOULD PARTICIPATE TO ACHIEVE KAIZEN”
…especially theTOP management.
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11. Among the seven(7) tools/methods to
achieve kaizen,
… it is the 5S that is most applicable to
our everyday work and life.
Thus we employ to utilize this strategy,
and apply in our everyday life and work
to achieve kaizen.
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12. 5S – A HousekeepingTechniques and
Strategy
1. SEIRE (Sort)
2. SEITON (Systematize / Stabilize / Straighten)
3. SEISO (Sweep / Shine)
4. SEIKETSU (Sanitize / Standardize)
5. SHITSUKE (Self-discipline / Sustain)
CONCEPTS AND PRINCIPLES:
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13. What is 5S?
•5S means good housekeeping and
workplace organization
•It is a concerted company-wide or
organization-wide effort to maintain
the workplace clean, orderly and well-
organized.
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14. What is 5S?
5S is a systematized approach to:
organize work areas
keep rules and standards
maintain discipline
5S utilizes:
workplace organization
work simplification techniques
5S practice:
develops positive attitude among workers
cultivates an environment of efficiency, effectiveness
and economy
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19. What can you gain from 5S?
Practicing 5S brings benefit not only to the
company’s business but also to the people who
practice it.
• 5S makes your workplace more pleasant
• 5S makes you work more efficiently
• 5S improves your safety
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20. What can a company gain from 5S?
P 5S increases PRODUCTIVITY.
Q 5S improves QUALITY.
C 5S reduces COST.
D 5S makes DELIVERY on time.
S 5S improves SAFETY.
M 5S improves MORALE.
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21. Why 5S brings such benefits?
• 5S improves CREATIVITY of people.
• 5S improves COMMUNICATION among
people.
• 5S improves HUMAN RELATIONS among
people.
• 5S improvesTEAMWORK among people.
• 5S improves CAMARADERIE among people.
• 5S givesVITALITY to people.
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22. 5S PHILOSOPHY
Productivity comes from the
elimination of waste
It is necessary to attack the root cause
of a problem, not just the symptoms
Participation of everybody is required
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24. 1. SEIRE (SORT)
Sorting is a step that involves selecting what you need to
complete the job and removing everything else from your
work area.
Clearly distinguish needed (frequently used) items
from unneeded items and eliminate the later.
Taking out and disposing unnecessary items.
Sort/classify the items that you “need” from the
items that you “want or not needed”.
Dispose the items that you do not need and
regroup the items that you need..
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25. SEIRI (SORT)
PROCESS/PROCEDURE:
Step 1: - Look around your workplace with your colleagues.
- Decide and identify which items are unnecessary for you.
- Dispose of unnecessary items.
Step 2: - If you and your colleagues cannot decide if an item
is unnecessary, place a Disposal Notice on the item,
indicate the date and set the item aside.
Step 3: - After a certain period, check if the item is still needed
or not.
- If no one needs the item after 3 months, it only means
that the item is no longer needed hence, dispose the
item right away. 25Prepared by Solomon.E
26. NOTE:
• It is recommended that this approach be used
company-wide, involving people from different
departments.
• Never keep anything which is unnecessary to your
work.
• While looking around for unnecessary items in
your workplace, look at every nook and corner
like when you are looking for cockroaches.
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27. 2. SEITON (SYSTEMATIZE / SET IN ORDER / STRAIGHTEN).
This step customizes your workstation and
surrounding area to meet your work area needs.
Arrange remaining items so they are easy to select,
use, and to return to their proper location.
Keep needed items in correct place and sequence of
use to allow easy and quick retrieval.
Arrangement / organization of necessary items in
good order for use.
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28. SEITON (SYSTEMATIZE/SET)
PROCESS/PROCEDURE:
Step 1: - Make sure that all unnecessary items are eliminated
from your workplace.
- Decide where you can place necessary items.
-Take into consideration the flow of your work.
-Take into account the movement of carts or even
people passing your desk from this point of view to
ensure safe and efficient operation.
Step 2: - Place frequently needed items close to the user to
minimize effort and time wastage.
-Things that are not used often could be places
slightly farther away.
- Make a plan on these principles and locate/store
things accordingly. 28Prepared by Solomon.E
29. Placement of Materials/Equipment Based on
Frequency of Use
PriorityFrequency of Use How to Store
Low Less than once a year Throw away
Once a year or so Store in distant place
Average Once every 2-6 months
Once a month Store together some-
Once a week where in the office
High Once a day Carry or keep at
Once an hour your workplace
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30. STEP 3: - It is necessary to make sure that everyone in your
workplace knows where things are kept for efficient
use.
- Make a list of things with their locations.
- Label each drawer and cabinet to show what is
kept inside.
STEP 4: - Apply the same principles as in Step 3.
- Indicate the places where fire extinguishers are
located as well as passages for carts.
- Place warning signs for safety precautions.
NOTE:
Three Rules for Storage Space
• Get rid of all unnecessary items
• Decide proper storage layout/classification
• Standardize names
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31. Arrange necessary items in good order
prevent loss and waste of time
easy to find and pick up necessary items
ensure first-come-first-served basis
make production flow smooth and work
easy
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32. SEITON PRACTICES
Don’t place goods in frontage along passages
Store goods for first-in-first-out retrieval
Everything must have its location
Label items and their location systematically, mark
everything
Separate special tools from common ones
Frequently used items nearer to the user
Make things visible to reduce searching time, organize by
color
Keep space for safety equipment and evacuation passages
clear
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33. Classification
Things
not
needed
Things
needed
No potential use
Things used constantly
Potentially useful
or valuable
Things used occasionally
Requiring special disposal
Seldom used,
but still needed
Place as close
as possible
Place a little
further away
Immediate disposal
Consider where
useful and move
Enclose in a separate,
designated place
Arrange responsible,
inexpensive disposal
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34. 3. SEISO (SHINE / SWEEP).
This step is powerful because its purpose is to find the
reason why things become dirty. Emphasis is on the
removal of dust, dirt and grime to reveal the source
and eliminate it.
Clean it so that defects are so easy to spot and
eliminate.
Cleaning of the workplace, including tools and
equipment
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35. SEISO (SWEEP/SHINE)
PROCESS/PROCEDURE:
Step 1: - Determine the subject of clean up (what to clean)
e.g., location (storage, shelves, etc.), equipment,
space (passageway, room, etc.)
Step 2: - Assign persons responsible for clean up (who, where).
Step 3: - Determine the method of clean up (how to do it).
-Target the areas for cleaning (storage,
equipment and surroundings)
- Draw up a cleaning responsibility map
- Create a cleaning schedule.
Step 4: - Implement cleaning.
Step 5: - Make a daily 5-minute cleaning habit before going
home (Keep it simple and easy to understand.) 35Prepared by Solomon.E
36. NOTE:
• Do not wait until things get dirty.
• Clean your workplace; machines and
equipment, tools and furniture regularly.
• Put aside 3-minute of seiso per day.
• Be responsible for your own work area.
• Never throw anything and make it your habit.
• Cleaning is also checking.
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37. Clean your workplace completely
keep environmental condition as clean as the
level necessary for the products
prevent deterioration of machinery and
equipment and make checking of
abnormalities easy
keep workplace safe and work easy
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38. SEISO PRACTICES
Big Seiso ( Clean-Up Day )
3-5 minute cleaning daily
Assign owner to each machine
Combine cleaning with inspection
Make daily maintenance points clear by
providing visible instructions
Prevent causes of dust and dirt
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39. 4. SEIKETSU (SANITIZE / STANDARDIZE).
This step creates a work area free of checklists; if good
standards are put in place it will be easier to maintain
and continue improving.
Set easy-to-follow standards and develop a structure to
support the three first (S’s) pillars.
Maintaining the workplace in high standard of
housekeeping and organization.
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40. SEIKETSU (SANITIZE/STANDARDIZE)
PROCESS/PROCEDURE:
Step 1: - Establish standards for maintaining compliance
with 3S.
- Remember the 3 “NO” principles:
No unnecessary items
No mess
No dirt
Step 2: - Make a schedule for cleaning your workplace.
Step 3: - Interdepartmental competition and cooperation is a
very effective means of sustaining and enhancing
people’s interest in 5S
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41. SHITSUKE (SUSTAIN/SELF-DISICPLINE)
PROCESS/PROCEDURE:
Step 1: - Create reasonable rules.
Create reasonable rules of behavior in the
workplace. Engage everyone concerned in the
creation of rules not just the department heads or
supervisors.
Discuss the rules with everyone concerned. This
will result to a feeling of involvement.
Show rules and standards clearly and attractively
using illustrations, photographs and color-coding.
Step 2: - Exhibit before and after 5S photos where everyone
will see them.
Step 3: - Recognize good practices and good performance.
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42. Maintain a high standard of housekeeping
and workplace organization at all times.
Maintain cleanliness and
orderliness
Prevent misoperation
Make it easy to find out
abnormality
Standardize good practices
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43. SEIKETSU PRACTICES
Visual control signs
Color coding
Maintenance labels
Fixed-point photography
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44. 5. SHITSUKE (SELF-DISCIPLINE / SUSTAIN).
Sustaining is the end result of how well we have
performed the previous four S’s. In the sustainability
stage, think of ways to eliminate effort in maintaining
an area.
Educate people so that 5S expands beyond initial limits
and turns into natural standard behavior.
Doing things spontaneously without being told.
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45. Safety Helmet
Head Lamp
Clean UniformTrain people to follow good
housekeeping rules autonomously.
(SHITSUKE)
SELF-DISCIPLINE
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46. • Enhance autonomous management activities
• Maintain the discipline needed to do a good job
• Upgrade productivity and quality consciousness
(SHITSUKE…)
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47. SHITSUKE PRACTICES
Wash hands after going to the toilet
Wash hands before and after meals
Eat and smoke at designated places
Keep workplace always clean and tidy
Wear clean uniform and shoes
Follow safety rules
Put things back in their proper places
Work according to standards
Observe proper office decorum
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48. BENEFITS OF 5S
• A clean and organized workplace ..….
• High in PRODUCTIVITY
• Produces QUALITY products and services
• Reduces COST to a minimum
• Ensures DELIVERY on time
• SAFE for people to work in
• Makes employee MORALE high
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49. 5S inWORK STATIONS
VISIBLE RESULTS:
• Decrease in the number of accidents and close calls
• Proper storage
• Improved productivity
• Greater people involvement in improvement activities
• Better use of floor space
• Early detection of problems
• High product quality
• Decreases delay
• Low employee turnover
• Low machine breakdown rates
• Detection system
• Zero breakdown
INVISIBLE RESULTS:
• Happier employees with high morale.
• Happier customers. 49Prepared by Solomon.E
50. “GOOD, BETTER, BEST
NEVER LET IT REST
TILL THE GOOD IS BETTER
AND THE BETTER IS BEST”
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