5S Training

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By: rameshkandan (46 month(s) ago)

send this ppt to my mail id saravanan.murthy@sonagroup.com Sarvanan

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Slide 1: 

1 Welcome to the workshop of Team- OED 5S

Training ModuleQuality Matters! : 

Training ModuleQuality Matters! “Alone we are weak, together we are strong. Together we shall work with our hands, as a family, in mutual trust and responsibility. Progress can be achieved only if we are ever ready to change ourselves. Working in a company is all about teamwork”. 1

Lets Know each other well: : 

Lets Know each other well: Your Name Department Organizations you have worked in before Total Experience Hobbies & Interests 3

Objectives : 

Objectives By the end of this program we will be able to:   Understand & practice the steps involved in “Workplace management” through “5S” supported by “Continuous Improvement” and “Mistake Proofing” techniques. 4

Work Place Management – 5 S : 

Work Place Management – 5 S Aim:- To create a standard, efficient & effective workplace for all employees 5 5S

1st S- “SORT” (SERI) : 

1st S- “SORT” (SERI) What do you understand by this ??? 6

1st S- “SORT” (SERI) : 

1st S- “SORT” (SERI) Not Needed At All Needed But Not Now Needed But Not Here Needed But Not So Much Quantity Red Tag Tactic : Visual Sorting. 7

1st S- “SORT” (SERI) : 

1st S- “SORT” (SERI) 8 Decide what you need Remove unnecessary clutter All tools, gauges, materials, classified and then stored Remove items which are broken, unusable or only occasionally used

1st S- “SORT” (SERI) : 

1st S- “SORT” (SERI) 9 Not Needed At All Needed But Not Now Needed But Not Here Needed But Not So Much Quantity PRINCIPAL For Sorting

1st S- “SORT” (SERI) : 

1st S- “SORT” (SERI) 10

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) : 

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) Arrange a place for everything. Everything in its place. What do you understand by this ??? 11

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) : 

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) Arrange a place for everything. Everything in its place. 12 ONCE YOU HAVE ELIMINATED ALL THE UNNEEDED ITEMS NOW TURN TO THE LEFT OVER ITEMS

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) : 

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) Arrange a place for everything. Everything in its place. 13 Organise layout of tools and equipment Designated locations Use tapes and labels Ensure everything is available as it is needed and at the “point of use”

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) : 

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) Arrange a place for everything. Everything in its place. 14 Workplace Checkpoints:- Positions of aisles and storage places clearly marked? Tools classified and stored by frequency of use? Pallets stacked correctly? Safety equipment easily accessible? Floors in good condition?

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) : 

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) Place for everything & Everything in its place. SHADOW BOARD 15

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) : 

Seiton & Visual Management Floor Markings 2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) 16

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2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) 17

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) : 

2nd S- “Set In Order” (Seiton - SYSTEMATIC ARRANGEMENT) PROPERLY ARRANGED FRUITS 18

3rd S- “SHINE” (SIESO) : 

3rd S- “SHINE” (SIESO) What do you understand by this ??? 19

3rd S- “SHINE” (SIESO) : 

3rd S- “SHINE” (SIESO) 20 Create a spotless workplace Identify and eliminate causes of dirt and grime – remove the need to clean Sweep, dust, polish and paint

3rd S- “SHINE” (SIESO) : 

3rd S- “SHINE” (SIESO) Maintaining a spotless workplace 21

3rd S- “SHINE” (SIESO) : 

Treat all areas/ documents/ stationeries etc. as family treasures 3rd S- “SHINE” (SIESO) 22

4th S –”STANDARDIZE” (Sieketsu) : 

4th S –”STANDARDIZE” (Sieketsu) What do you understand by this ??? 23

4th S –”STANDARDIZE” (Sieketsu) : 

4th S –”STANDARDIZE” (Sieketsu) 24 Generate a maintenance system for the first 3 S Develop procedures, schedules, practices Continue to assess the use and disposal of items Regularly audit using checklists and measures of housekeeping Real challenge is to keep it clean

5th S- “SUSTAIN & TRAIN”(SHITSUKE) : 

5th S- “SUSTAIN & TRAIN”(SHITSUKE) 25

5th S- “SUSTAIN & TRAIN”(SHITSUKE) : 

5th S- “SUSTAIN & TRAIN”(SHITSUKE) 26 Means inoculate courtesy & good habits Driving force behind all 5S Make it a way of life Part of health and safety Involve the whole workforce* Develop and keep good habits

Benefits to Implementing 5S : 

Benefits to Implementing 5S 27 WHAT U HAVE COME ACROSS AT THE END NEAT & CLEAN WORKPLACE SMOOTH WORKING NO OBSTRUCTION SAFETY INCREASES PRODUCTIVITY IMPROVES QUALITY IMPROVES WASTAGE DECREASE MACHINE MAINTENANCE VISUAL CONTROL SYSTEM EMPLOYEES MOTIVATED WORKSTATIONS BECOME SPACIOUS 27

Let us compare!! : 

Let us compare!! BEFORE 5S AFTER 5S 28

Let us compare!! : 

Let us compare!! BEFORE 5S AFTER 5S 29

Let us compare!! : 

Let us compare!! BEFORE 5S AFTER 5S 30

Examples of 5 S in your day to day Work : 

Examples of 5 S in your day to day Work Your Wallet Your Cabinet Your Work desk Your Computer Home Page Your Kitchen…… Lets us try 5S with our wallet? 31

Small Improvements : 

Small Improvements Small Improvement done at your work place to make the work easier. 32

Slide 33: 

Continuous Improvement- few examples BEFORE AFTER 33

Slide 34: 

Continuous Improvement- few examples 34

Slide 35: 

Continuous Improvement- few examples 35

Slide 36: 

Continuous Improvement- few examples 36

Slide 37: 

Error Proofing Techniques 37

Slide 38: 

( Control ) ( Control ) ( Control ) Error Proofing Techniques 38

Slide 39: 

3.5 inch diskette cannot be inserted unless diskette is oriented correctly. This is as far as a disk can be inserted upside-down. ( Shut down) Warning lights alert the driver of potential problems. These devices employ a warning method instead of a control method. Even bathroom sinks have a mistake-proofing device. It is the little hole near the top of the sink that helps prevent overflows. ( Control ) Error Proofing Techniques 39

What have we understood in 5S : 

What have we understood in 5S 1st S- “SORT” Only to have in the area what is required for the process .( Red tagging ) 2nd S- “Set In Order” Place for everything. Everything in its place. Color Coding, Floor Marking, Signage, Flow Directions 3rd S- “Shine” To prevent dirt & contamination from reoccurring by eliminating the sources of dirt & by making cleaning everyday work activity Cleaning and making the area Spik & Span 4th S- “Standardize” Ensure that the current standards achieved for Sort, Set in Order & Shine are monitored and maintained. Eg- Road Signages standardization 5th S- “Sustain & Train” Every employee contributes to sustaining the rate of improvement. Audit Sheets, Training Programmes Resistance & Benefits of implementing 5 S 40

Slide 41: 

5 S is not a ‘one off’ activity; it should be part of our everyday activities! 41

Slide 42: 

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Slide 43: 

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Thank you : 

Thank you Lets do some practical learning now ……… 1