5S Program

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WORKPLACE EXCELLENCE THROUGH 5S K S Madhavan & Associates January 2007

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What is a Workplace ? Workplace is – - “where one works” - “where there is an output” - “where there is creative activity” & - “where value is being added”

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Workplace is where you do service for the organisation in many forms, such as – Developing a Plan Creating a Strategy Designing a Product Developing a System Producing a product Creating a Document Compiling Data

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Workplace is the reflection of your personality

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Employees can contribute and create quality output much more effectively - Where there is proper organisation Where there is a clean environment. Where there is a serene atmosphere Where the psychological environment is conducive Where the activities are streamlined.

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Surroundings Cleanliness of the place People with whom one works Systems through which we interact Atmosphere – Heat, Light, Ventilation, Dust, Humidity etc. Cultural background of place Ambience – visual and psychological. Physical & Psychological Environment comprise the following -

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Fulfilling Acceptable Satisfying Where one feels needed Where we are seen to be efficient and professional Where we feel proud to work Psychological Environment should be

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5S changes the individual and brings orderliness in him resulting in a clean workplace, clean thinking and removes dirty work habits.

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Why we don’t focus on our workplace ? Lack of Concern for the workplace Don’t give importance to cleanliness and orderliness. Don’t feel the need Don’t bother to keep things Neat & Tidy Cleanliness is not our priority Dirtiness is effortless – Cleanliness needs dedication We don’t stick to Self Discipline We do not take pride in our work We are not proud of our workplace Simply stated, we are not trained to recognise abnormalities and react to them.

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What is your workplace like? Before we learn more about 5S, let’s take a look at your workplace first. Which of the following best describes the present condition of your workplace? In my workplace, nobody throws things around. Everybody helps to keep the place clean. In my workplace, people do throw things around but there are cleaners who tidy up the workplace. In my workplace, everybody throws things around and there is nobody to clean the place up

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5S A SIMPLE DOWN TO EARTH JAPANESE CONCEPT

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An organisation is the SUM TOTAL of its work-places. If each workplace is excellent, the organisation would be excellent too Organisation Work Place Work Place Work Place Work Place Work Place

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In a normal organisation, only a few workplaces shine, some workplaces do not shine and most are mediocre.

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In a 5S organisation, all work places shine

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5S Seiri Sorting Out Seiton Systematic Arrangement Seiso Spic & Span Seiketsu Standardisation Shitsuke Self Discipline

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5S ENVIRONMENT PHYSICAL SYSTEMS INFORMATION

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WHY 5S ? 5S REVEALS ABNORMALITIES IN WORK PLACE

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IN A NORMAL COMPANY ABNORMALITIES ARE IGNORED INVISIBLE UNSOLVED UNTOUCHED

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IS TO PRACTICALLY RESPOND TO THEM, SUREST WAY TO ELIMINATE ABNORMALITIES AFTER IDENTIFYING/ SURFACING THEM

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THROUGH ON THE SPOT ACTION 5S TRANSFORMS WORKPLACE PRACTICALLY

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FOCUSSING ATTENTION ON ABNORMALITIES, CERTAINLY REDUCES THEM.

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ARE WE DOING ENOUGH for ASK - IMPROVING OUR WORKPLACE ?

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SHAKES UP THE ORGANISATION, (BE IT A FACTORY,OFFICE, OR ANY WHERE) & SHAPES ITS CULTURE CREATES NEW AWAKENING NEW AWARENESS SENSITIVITY TO MEDIOCRITY & LACKLUSTRE ENVIRONMENT 5-S

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5 S NEEDS Ideas Willingness Enthusiasm Focus

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5-S PHILOSOPHY 1. PROFITS IN THE WORK-PLACE . 2. WORK PLACE CENTERED APPROACH . EMPHASIS ON WORK PLACE . CONFIRM FACT AT THE WORK PLACE . 3. GROUP ACTIVITY CARREID OUT 4. RESPONDING TO THE NEEDS OF EMPLOYEES LIE HIDDEN WITH CO-OPERATION WITH PATIENCE WHERE EVERYONE ACTIVELY PARTICIPATES LEADING TO KAIZEN

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COMMON TOOLS THREE TARGETS OF ALL IMPROVEMENT PLANS SPECIAL TOOLS 5-S WORK STANDARDS ROUTINE SUPERVISION 7QCTOOLS Robust Desn. DR JIT VE QUA- LITY TIME COST FMEA TPM/ TQM

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5-S SEIRI = SORTING SEITON = SYSTEMATIC ARRANGEMENT SEISO = SPIC & SPAN SEIKETSU = STANDARDN. SHITSUKE = SELF-DISCIPLINE SORT OUT NECESSARY, UNNECESSARY & DOUBTFUL ITEMS TAKE DISPOSAL ACTION FOR UN NECESSARY & DOUBTFUL ITEMS ARRANGE NECESSARY ITEMS ONLY IN GOOD ORDER WITH EASY ACCESSIBILITY A PLACE FOR EVERYTHING & EVERY THING IN ITS PLACE CLEAN WORKPLACE COMPLETELY NO DUST NO DIRT AT SHOP FLOORS, PLANT & MACHINERY, COMPONENTS PRODUCTS, OFFICE EQPT. ETC MAINTAIN HIGH STANDARDS OF THE 3-Ss INTRODUCE CLEANING CALENDARS, CHECK LISTS & VISUAL CONTROLS SELF DISCIPLINE THROUGH HABIT FORMATION

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PRE-REQUISITES TOP MANAGEMENT COMMITMENT LEADERSHIP FROM CEO PERIODIC VISITS BY STEERING COMMITTEE TO 5S ZONES ALL PEOPLE TO PARTICIPATE ALL AREAS TO BE COVERED HIGH EMPHASIS FROM START 5-S WITH ‘KAIZEN’

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APPROACH AT THE SCENE OF THE PROBLEM CONSENSUS FORMULATION COLLECTIVE EFFORT “ BOTTOM - UP”

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ACTION PLAN OF 5S CREATE 5S AWARENESS AT ALL LEVELS FORM STEERING COMMITTEE & ZONES NOMINATE CHAMPIONS, FACILITATORS & LEADERS AUDITING & REWARDING TRAIN ONE AND ALL COMMUNICATION & PUBLICITY IMPLEMENTION

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5-S enables development of Multi-Layered Leadership

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TYPICAL BENEFITS OF 5S UNEARTHING ABUNDANT WEALTH FROM IDLE / DETERIORATING ASSETS - SEIRI (CREATES SPACE FOR EFFECTIVE USE) ORGANISING WORKPLACE AS PER THE CONVENIENCE OF EMPLOYEES & THE JOB -SEITON ( A PLACE FOR EVERYTHING & EVERYTHING IN ITS PLACE ) CREATING SERENE ATMOSPHERE -SEISO ( SPIC & SPAN)

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STANDARDISING ALL GOOD ACTIVITIES PURSUED THROUGH FIRST 3-Ss - SEIKETSU INCULCATING SELF-DISCIPLINE OF ALL EMPLOYEES THROUGH TRAINING & HABIT FORMATION - SHITSUKE TYPICAL BENEFITS OF 5S

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5S PROFITS TEI TQM TPM ELIMINATES WASTE

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5-S practice is a pre-requisite for - Total Quality Management Total Productive Maintenance Occupational Health & Safety Systems Quality Management System Environment Management System etc Social Accountability Audit

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QUALITY SHE EFFICIENCY EQUIPMENT MATERIALS TOOLS, JIGS, FIXTURES METHODS WORKERS PRODUCTS TIMELINESS 5-S CUSTOMER SATISFACTION EMPLOYEE SATISFACTION MOTIVATES MAX. UTILISATION IMPROVES PROMOTES GOOD MAINTAINS UPKEEPS

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DAILY 5- MINUTES 5-S

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5 S IS NOTHING BUT ORGANISED COMMON SENSE