Applying 5S to a college lab and recommendations based on 5S

1. Qimpro Champion League:
Challenge 1: 5S
(COLLEGE LAB)
INDIAN INSTITUTE OF FOREIGN TRADE (IIFT)
Pranjal
Parihar
Vivek
Maheshwary
Anukriti
Singh

2. WHAT IS 5S???
 Name of the workplace organisation method
 Identified as one of the techniques that enabled just in time manufacturing
 5S stands for five Japanese words all starting with English letter ‘S’
 Seiri (Sort)
 Seiton (Set in Order)
 Seiso (Shine)
 Seiketsu (Standardize)
 Shitsuke (Sustain)
ADVANTAGES OF 5S
 Reduce workflow problems.
 increases product quality and productivity
 Improve workplace safety
 Align employee efforts with goals and strategies for eliminating waste.

3. 1S. SORT
Separate necessary
items and the
unnecessary items
and dispose
unnecessary items
properly
2S. SET IN ORDER
Arranging all the
items in a particular
order for easy use and
reduce searching time
for a particular tool
3S. SHINE
Cleaning the
workplace and
maintaining its
appearance daily by
establishing
preventative
measures to produce
on going cleanliness
4S. STANDARDIZE
Maintain and make
the ‘sort’ ,’ set in
order’ and ‘shine’
habitual. 5S
becomes a part of
regular work routine.
5S. SUSTAIN
Ongoing application
of knowledge , skills
and abilities gained
from 5S process.
Improving
organisational
effectiveness.
5S

4. POOR 5S PRACTICES
1. SORT
 Necessary items are mixed with
unnecessary items
 Unnecessary items are lying in
the work area
2. SET IN ORDER
 No differentiation between
necessary tools, equipment, etc.
 Location of unnecessary items
are not clearly defined
 No Designated & permanent
locations for items

5. 3. SHINE
 The area is not cleaned thoroughly
 Cleaning & inspection of areas are not
taking place daily
4. SUSTAIN
 No proper SOPs are there;
 There is no proper documentation of
equipment & processes
 No audit schedule is there
POOR 5S PRACTICES contd.

6. QUANTIFICTION OF THE PROBLEM
21%
16%
28%
35%
SET IN ORDER
Not keeping the set
up for experiments in
order
Not arranginging
students in group in a
systematic order
Irregular sequence of
experiments
performed (theory
lags behind pratical
sessions)
Not keeping the
equipemnts in proper
place
47 hours Increase in time for
conducting lab experiments (monthly)
because of not following SORT. Above
reasons causing the % of time
occupied in SORT.
30 hours Increase in time for
conducting lab experiments
(monthly) by not following SET.
Above reasons causing the % of time
occupied in SET.
33%
51%
16%
SORT
Searching time for
instruments
Seprating
Necessary items
from unnecessary
items
Removing
Unncessary items
from work area

7. 43%
26%
31%
SHINE
Not wearing lab
coats, goggles
and gloves
No daily cleaning
of the floor
No regular
cleaning of the
working area
16 hours Increase in time for
conducting lab experiments
(monthly) because of not following
SHINE. Above reasons causing the %
of time occupied in SHINE.
QUANTIFICTION OF THE PROBLEM
12 hours Increase in time for
conducting lab experiments
(monthly) because of not following
STANDARDIZE. Above reasons
causing the % of time occupied in
STANDARDIZE.
20%
27%33%
20%
STANDARDIZE Not sticking
quipment name on
respective
equipments
No proper SOPs
No full time lab
assistants
No proper record
keeping of the
equipments

8. SUSTAIN:
 Because of above problems, approximately 105 hours are wasted
for conducting lab experiments (monthly). It does not add any
value.
 Using of 5S technique and continuously improving above, reduces
this wastage time
 Effective utilization of human resources can be increase by using
this technique
QUANTIFICTION OF THE PROBLEM

9. RECOMMENDATIONS
1. SORT
 Establish a holding area for items (Red Tag area)
 Identify items not required at the current location, if at all
 Team members evaluate items in Red Tag area
2. SET IN ORDER
 Define the major processes (experiment) performed
 For each process, draw a map of the locations of each activity
 Identify sources of waste and corrective measures
 Position items where they are needed based on frequency

10. 3. SHINE
 Fix leaks & other problems
 Inspect daily
 Fix potential issues before they become major problems
4. STANDARDIZE
 Develop SOPs
 Document equipment & processes
 Develop audit schedule and assign tasks to individuals
 Establish a methodology to ensure consistent strategy for 5S
implementation
RECOMMENDATIONS

11. 5. SUSTAIN
 Daily Checklist which looks at the cleaning of equipment and floor,
no unnecessary items, location and position of tools and storage,
condition of storage area
 Weekly/Fortnightly Audit of lab by Non-lab personnel formally check
for things out of place, using same checklist
 Lab In-charge: Taking Informal Walks through Lab to look for
potential problems,
 A Visual Board: To Show information about & results of 5S
RECOMMENDATIONS

12.  How to quantify the general problem in the terms of time and cost
 Advantages of 5S in industry perceptive
 How to identify and separate the problems.
 Good 5S Practices proves to be the best if they are brought in
application.
 Implementation of 5S technique in daily life .Better organize
ourselves by like pasting stickers on books to differentiate them
clearly in the rack, keeping our surroundings, room and study table
clean etc.
 Utilization of resources in a effective manner
 How to use bar and pie chart for quantifying the problem
 Help the students to face the competitive world in future.
 Working in a team and sharing and exchanging ideas with team
members.
LESSONS LEARNED BY THE TEAM

13. THANK
YOU