5s

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5S is a method that uses five Japanese words which start with the letter S Seiri – Sort Seiton – Set in Order Seiso – Shiny clean Seiketsu – Standardized cleanup Shitsuke - Sustain

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Presentation Transcript

Slide 1:

5S Prepared by M.Ganesh Murugan 9715447621 1 MGM

Slide 2:

Necessity of 5S SEIRI SEITON SEIKETSU SEISO SHITSUKE Productivity improvement Quality assurance Cost reduction Secure production volume Deadline observation Happy workplace Job satisfaction Workplace improvement 5S 2 MGM

The 5 Words:

The 5 Words 5S is a method that uses five Japanese words which start with the letter S 5S 3 MGM

5 S 5 Steps to a Better Workplace:

5 S 5 Steps to a Better Workplace 5S 4 MGM

Why 5 S?:

The Purpose of 5S is to promote a safe and efficient work environment Not just a cleaning campaign, 5S is a way to set a new standard that we all agree on and help us get the discipline we need to maintain it. By Implementing the 5S Opportunity to improve the own workplace Team involvement & Problem solving opportunities appears. 5S gives visible and Motivating Results First step in the implementation of Lean Manufacturing, TPM an Kaizen. Why 5 S? 5S 5 MGM

Reasons to implement 5S:

Improved Safety No items on the floor Therefore fewer slips or falls Safety device in their right places Less dust Reasons to implement 5S 5S 6 MGM

Reasons to implement 5S:

Improved Safety Fewer break downs Fewer “strange ” errors from electronic systems Less wear from dust or grit in moving parts Reasons to implement 5S 5S 7 MGM

Reasons to implement 5S:

Improved Safety Fewer break downs Better work Environment A clean & well functioning workplace Fix the unsafe & cluttered work stations Reasons to implement 5S 5S 8 MGM

Reasons to implement 5S:

Improved Safety Fewer break downs Better work Environment Less Environmental Impact Leakages such as oil will easily be spotted Using less floor space may reduce energy consumption Reasons to implement 5S 5S 9 MGM

Reasons to implement 5S:

Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors Easy to do it right than wrong Safety guards placed properly Less clutter, fewer visual distractions& easy access to tools and materials Reasons to implement 5S 5S 10 MGM

Reasons to implement 5S:

Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier When you do 5S , you inspect the same Reasons to implement 5S 5S 11 MGM

Reasons to implement 5S:

Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier No searching Effective tools at the right place Reasons to implement 5S 5S 12 MGM

Reasons to implement 5S:

Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier No searching Higher morale Through teamwork and visible results Reasons to implement 5S 5S 13 MGM

Reasons to implement 5S:

Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier No searching Higher morale Goodwill Helpfulness to create an impression. Reasons to implement 5S 5S 14 MGM

The 5 phases in 5S:

The 5 phases in 5S 5S 15 MGM

Step 1 - Sorting:

Step 1 - Sorting 5S Sorting is a team activity that will be carried out by the production an d maintenance personnel together Sorting has two purposes Remove unnecessary objects Reduce waste 16 MGM

Remove unnecessary Objects:

Remove unnecessary Objects 5S Go through the whole plant Look for Materials Behind or under machines Rejects Forgotten materials 17 MGM

Remove unnecessary Objects:

Remove unnecessary Objects 5S Go through the whole plant Look for Materials Tools Not in use Worn out or broken “Custom-made” tools (made of steel wire/tape/etc-Replace by real tools 18 MGM

Remove unnecessary Objects:

Remove unnecessary Objects 5S Go through the whole plant Look for Materials Tools Spare parts Broken Surplus Inventory Spare parts for machines no longer in use 19 MGM

Remove unnecessary Objects:

Remove unnecessary Objects 5S Go through the whole plant Look for Materials Tools Spare parts Out-of-date Documentation Instructions Binders Manuals 20 MGM

Remove unnecessary Objects:

Remove unnecessary Objects 5S Go through the whole plant Look for Materials Tools Spare parts Out-of-date Documentation Bulletin board Outdated notices Irrelevant information 21 MGM

Remove unnecessary Objects:

Remove unnecessary Objects 5S Go through the whole plant Look for Materials Tools Spare parts Out-of-date Documentation Bulletin board Other stuff Outdated computer hardware Packing Material Outdated protective equipment 22 MGM

Remove unnecessary Objects ?:

Remove unnecessary Objects ? 5S Look at each object Ask yourself, Do we need it at all? If not – Discard it or sell it Ask yourself, Will we need it soon? If not – Put it in proper storage eg :- spare parts, etc. Is it working , but.. Too difficult to use In correct design Too time consuming to use Has a high risk for injury/quality? Not easy to accessible 23 MGM

Remove unnecessary Objects ?:

Remove unnecessary Objects ? 5S Each item to be discarded or corrected is marked with a red tag 24 MGM

Waste elimination:

Waste elimination 5S The second purpose of sorting is to reduce waste and generate ideas for improvements We will try to identify every thing that is hindering us from working safely and efficiently 25 MGM

Waste elimination:

Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instrutions Do we have them? Are they up-to-date? Are they in use? If not – why not? 26 MGM

Waste elimination:

Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety What measures should we take to eliminate the risk of fire and accidents? Remove clutter Improve unsafe electrical installations Replace broken safety devices Repair broken components 27 MGM

Waste elimination:

Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety Environment What measures do we need to minimize or prevent damage to the environment? 28 MGM

Waste elimination:

Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Anything missing ? Anything not working properly ? Anything in need of improvement? 29 MGM

Waste elimination:

Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Inconvenient work positions Seat & work s/ f’s at the right height Awkward angles for moving materials 30 MGM

Waste elimination:

Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Inconvenient work positions Deferred maintenance Temporary repairs/not properly secured Old equipments/technical errors 31 MGM

Waste elimination:

Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Inconvenient work positions Deferred maintenance Improvement Proposals Review prior suggestions 32 MGM

Waste elimination:

Waste elimination 5S All identified waste items are marked with an red tag Machine tagged with errors and improved suggestions 33 MGM

5S Sort list:

Tag no Item description Session tagged Date Tagged by Responsible Due date 5S Sort list 5S Every tag refers to a 5S Sort list Think break Do we have any examples of deferred maintenance in our plant? 34 MGM

Question yourself – Seiri:

Question yourself – Seiri 5S Do you find items scattered at your place? Are any items left in disorganized way? Are all item sorted and kept in designated place? Are tools and stationeries properly sorted and stored? 35 MGM

Step 2 – Set in Order:

Step 2 – Set in Order 5S Every tag refers to a 5S Sort list 36 MGM

Missing letter ?:

Missing letter ? 5S Every tag refers to a 5S Sort list 37 MGM

Why-set in order?:

Why-set in order? 5S The purpose of Seiton – set in order is that everything that we regularly use should have a convenient placement Tools should be kept at the point of use No bending to pickup or move materials Alter flow paths to improve efficiency 38 MGM

Placement:

Placement 5S 39 MGM

Efficient layout and color coding:

Efficient layout and color coding 5S Make a drawing of the current situation Brainstorm to find an optimal layout Agree the color code Mark the location(removable tapes preferred) of all objects Move the equipments if necessary 40 MGM

Question yourself – Seiton?:

Question yourself – Seiton ? 5S Are passages and storages clearly indicated? Commonly used tools & stationeries separated from the seldom used? Are containers, boxes, materials and fire extinguishers stocked up properly? Are there grooves, cracks or bumps on the floor which hinder work or safely? 41 MGM

Step 3 – Shiny clean:

Step 3 – Shiny clean 5S Next step in 5S is to carry out a Shiny clean event 42 MGM

Shiny clean:

Shiny clean 5S To keep your area clean on a continuing basis Clean all machines thorough Clean all equipments, fixtures, and tools Clean the floor, walls, cabinets, shelves etc. 43 MGM

Why – Seiso?:

Why – Seiso? 5S To prevent the area from getting dirty in the first place, so we don’t have to clean it up afterward A clean workplace is indicative of a quality product and process Dust and dirt cause potential health hazards Things to remember :- Sweep/Vacuum Dust / Mop 44 MGM

Guidelines – Seiso?:

Guidelines – Seiso? 5S Divide areas into zones Define responsibilities for cleaning Tools and equipment must be owned by an individual Focus on removing the need to clean 45 MGM

Question yourself – Seiso?:

Question yourself – Seiso? 5S Are machines and equipments dirty? Are pipes dirty and corroded? Are nozzles dirtied by lubricants and ink? Are shades, lights, bulbs, and light reflectors dirty? 46 MGM

Step 4 – Standardized cleanup:

Step 4 – Standardized cleanup 5S Continue sorting, storing and cleaning to maintain serene atmosphere at all times 47 MGM

Why – Seiketsu?:

Why – Seiketsu ? 5S Prevents regression back to an unclean/disorganized environment Things to remember :- Develop schedules, checklists Periodically evaluate area using 5”S” Audit sheet Continually improve neatness 48 MGM

Phases of Seiketsu?:

Phases of Seiketsu ? 5S Clarification of vital points for management Things to remember :- What are the minute defects? Basic conditions: Cleanliness, refueling, replace tightly bind fast, dirt, looseness Operating conditions: pressure, temperature, time, flow volume, weight, Equipment, jigs and tools, sub-materials 1 49 MGM

Phases of Seiketsu?:

Phases of Seiketsu ? 5S Prepare standards for the conditions Objectification of judgment standards for normal versus abnormal Judgment without using measurement, knowledge, intuition and knack 2 50 MGM

Phases of Seiketsu?:

Phases of Seiketsu ? 5S Judgment standards for abnormalities Inspection methods that can be used by anybody Methods for actions against abnormalities 3 51 MGM

Question yourself – Seiketsu?:

Question yourself – Seiketsu ? 5S Are there sufficient light? Is there noise/light in your place causing discomfort? Do people work at designated way? Is there any leakage? 52 MGM

Step 5 - Shitsuke:

Step 5 - Shitsuke 5S 53 MGM

Shitsuke:

Shitsuke 5S To maintain discipline, we need to practice and repeat until it becomes a way of life 54 MGM

Shitsuke:

Shitsuke 5S Make sure you stick to standard procedures and make them a habit Be disciplined to follow rules and regulations to maintain standards 55 MGM

Why – Shitsuke?:

Why – Shitsuke ? 5S To build “housekeeping” into every day process Makes the 7 wastes visible Gets everyone involved Things to remember :- Training everyone is vital Involvement from all is necessary Commitment and discipline toward housekeeping is essential in taking the first step in being World Class 5 “S” RATING 0= Poor (Unacceptable) 2= Satisfactory 4= Excellent ( World Class Environment) 56 MGM

Question yourself – Shitsuke?:

Question yourself – Shitsuke ? 5S If 4S done? Are regular 5s check conducted? Do people involved without reminder? Do assemble at time? 57 MGM

Action Plan for Implementing 5S:

Action Plan for Implementing 5S Awareness programme of 5s for all employees, supervisors, engineers and managers. Form steering committee Application programme on 5S for all Employees Steering committee periodically evaluates all cells, scores displayed on the display board Display posters on house keeping, distribute cards on 5S to all employees Annual award for the best cell 5S 58 MGM

Advantages of 5S:

Advantages of 5S If tools and materials are conveniently located in uncluttered work areas Operators spend less time looking for items This leads to higher workstation efficiency, a fundamental goal in mass production A clean and tidy workplace leads to greater well being and increased motivation Company image improves Time saving Quick retrieval Accidents & mistakes minimized Increases space Creates workplace ownership Foundation of all qc tools Continuous quality improvement Lean manufacturing Visual management system Results in a place easier to manage Smooth working no obstruction 5S 59 MGM

Checking System:

Checking System 5S 5S Audit 60 MGM

5S Audit:

5S Audit 5S Three purposes of conducting regular 5S Audit reviews are: Review compliance to the 5S standards for your factory Note and address non-compliance – to fix what is wrong! Provide a formal opportunity to suggest improvements 61 MGM

The Basic Steps:

The Basic Steps 5S Plan for the audit by dividing the workplace into various areas, probably the same ones where different teams conducted the various 5S stages. Make a checklist for each area, based on the standards that were set during 5S . Find out the list of known problems in each area. From the initial 5S sweep, this may include: Machines needing repair Tool racks Signage on tool racks or cabinets or storage shelves; warning signs; “keep clear” markings for corridors; or instruction pages Surplus equipment or materials which were not immediately removed 62 MGM

During the audit, three key tasks:

During the audit, three key tasks 5S ONE Determine whether known problems have been addressed: Does this machine still leak lubricants? Has the required tool rack been installed in this area? Is it labeled? Is it full? Are tools still left on workbenches? Is the warning sign in place so people will not walk under this crane? Why is this outdated drill press still in the corner? 63 MGM

During the audit, three key tasks:

During the audit, three key tasks 5S TWO See that standards are being met: Are tools left on workbenches? Is something missing from a tool rack? Is dirt accumulating somewhere? Are existing labels still visible and easily read? (This is especially important for signs that may be obscured by dust, and for lines painted on floors where they can be scuffed) Are there new sounds or smells that indicate that gears are grinding or fluids are leaking? 64 MGM

During the audit, three key tasks:

During the audit, three key tasks 5S THREE Note what has not yet been standardized – this is the most creative and difficult part, because it may involve seeing what is missing in an area that seems tidy: Why is there no sign over the neat stack of work-in-process materials on that shelf? (How will the next shift know what is there, or what should go there?) Tools that are not yet labeled Is there a limit to how high those barrels can be stacked? Why don’t we show that information on the sign for that storage area? Do we need all those cans of wing nuts in this assembly area? How many are used in one day? Should the rest of the month’s supply be stored elsewhere? 65 MGM

Safety infractions should also be part of the 5S audit:

Safety infractions should also be part of the 5S audit 5S Are WHMIS (Workplace Hazardous Materials Information System) labels used properly? Are fire exits visible and clear? Are the fire extinguishers charged and inspected on schedule? Are stairs and ladders safe? Do we notice unsafe behavior regarding heights and falls? Climbing a ladder without maintaining three points of contact? Working on a height without the required safety tether? 66 MGM

To follow up on each 5S audit:

To follow up on each 5S audit 5S Write up a work order to deal with each deficiency Update the next check list: Check off what was corrected Add new deficiencies to be reviewed Determine the score: Deduct for each deficiency Add a point for each correction Add a point for each suggestion for improvement If the previous audit had found deficiencies, the goal is to eradicate them The ultimate goal is to regularly achieve zero outstanding deficiencies 67 MGM

How often should audits be Performed?:

How often should audits be Performed? 5S Regular audits lead to the best results: Weekly “self-check” audits by teams of workers, reviewing their own areas This might be the best way to generate suggestions for improvements Monthly audits by the area supervisor Ensure that the weekly audits catch any problems with the daily or weekly cleanups Pay special attention to the less-frequent cleaning tasks Try to notice what is missing: new tools that do not yet have a place in a rack; materials stored neatly but not well-labeled 68 MGM

How often should audits be Performed?:

How often should audits be Performed? 5S Quarterly audits by the plant manager Ensure that standards are being met If there are deficiencies, ask “why”: try to determine the root causes Ensure that resources are allocated to repairs and to making the long-term improvements Without audits, it is impossible to ensure compliance. 69 MGM

5S Audit check sheet:

5S Audit check sheet 5S Model follows 70 MGM

Slide 71:

71 MGM

Slide 72:

Prepared by M.Ganesh Murugan 9715447621 72 MGM