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Kortek Let’s Win Customers
Understanding 5S
Presented By : ( Mr. D G Amle / Quality )Date: 12th Jun’2010
Kortek Let’s Win Customers
WHAT PROBLEMS DO U COMMONLY
ENCOUNTER AT YOUR WORKPLACE
HIGH ABSENTEEISM HIGH TURNOVER DEMOTIVATED EMPLOYEES DISORDERED/ CLUTTERED ENVIRONMENT MISTAKES/ERRORS
Kortek Let’s Win Customers
THE SOLUTION TO ALL THESE PROBLEMS IS
5S
5S Is the HOUSEKEEPING TECHNIQUE
PRODUCTIVITY AND SAFETY ENHANCEMENT TECHNIQUE
Kortek Let’s Win Customers
IDEA BEHIND 5SIDEA BEHIND 5S
• IN ORDER TO ACHIEVE HIGH LEVELS OF QUALITY, SAFETY AND PRODUCTIVITY, WORKERS MUST
HAVE A HEALTHY WORKING ENVIRONMENT
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1. 5S Goal & Definition1. 5S Goal & Definition
2. 5S obstacle2. 5S obstacle
3. Fixation point3. Fixation point
4. Expectation effect4. Expectation effect
5. Details 5. Details
1)Sort(SEIRI) 2)Set In Order (SEITON)1)Sort(SEIRI) 2)Set In Order (SEITON)
3)Shine(SEISO)3)Shine(SEISO) 4)Standardize(SEIKETU) 4)Standardize(SEIKETU)
5) Sustain (SITSUKE)5) Sustain (SITSUKE)
6. Standard & example 6. Standard & example
6Kortek Let’s Win Customers
ContentsContents
All actions that do not occur added value in manufacture activity are waste.
The waste only raises a cost.
5S reduce a waste.
The goal of 5S are fundamental improvement of person, equipment, environment and enterprise.
The center of improvement is person, and the build up-awareness for all members is first.
7Kortek Let’s Win Customers
1. 5S Goal & 1. 5S Goal &
DefinitionDefinition
8
Efficient work-placeEfficient work-place Target achievementTarget achievement
Follow Work standard
Improve Workmethod
Think idea forWaste removal
Think idea for Waste searching
Improve Equipment availability
Analyze & record Work information
Make Clean
workplace
Create Lively
atmosphere
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1. 5S Goal & 1. 5S Goal &
DefinitionDefinition
9
The type of waste in the field (The 7 waste of The type of waste in the field (The 7 waste of Toyota)Toyota)
1. Over-production Waste 2. Waiting Waste
3. Transporting Waste
3. Processing Waste
6. Motion Waste 7. Defects Waste
5. Inventory Waste
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1. 5S Goal & 1. 5S Goal &
DefinitionDefinition
10
What is 5S ?
Sort /Sorting (SEIRI) : Distinguish necessary and unnecessary item
→ Remove unnecessary and non-urgency item
Set In Order /Systematic Arrangement(SEITON) : Be use at any time
within 30 seconds
→ Every tool should have a place. Draw outlines on the wall or floor for easy recognition
Shine /Cleanliness(SEISO) : Cleaning → Make anyone can find defect
Standardize/Maintenance (SEIKETU) : 5S activity standardization → Maintain
clean condition
Sustain /Self Discipline (SITSUKE) : Ongoing improvement
→ Be habitual for procedures
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1. 5S Goal & 1. 5S Goal &
DefinitionDefinition
11
The 12 obstacles of 5S activity
Obstacle 1 – 『 Too late to do now! 』
Obstacle 2 – 『 Top mgmt. can not do such things 』
Obstacle 3 – 『 It will be dirty soon 』
Obstacle 4 – 『 Even if we keep clean or arranged, quality or productivity
does not rise 』
Obstacle 5 – 『 It is an uninteresting work 』
Obstacle 6 – 『 It have done already 』
Obstacle 7 – 『 Because I’m not uncomfortable, I’m okay 』
Obstacle 8 – 『 Such thing have done some years ago already 』
Obstacle 9 – 『 5S activities are issue of workplace 』
Obstacle 10 – 『 Because I’m busy, I have no time to do such things 』
Obstacle 11 – 『 I hate your order 』
Obstacle 12 – 『 Because profit remains, it is okay 』
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2. 5S Obstacle2. 5S Obstacle
12
The 7 major points to fixate 5S activity Point 1 – Top mgmt. is the responsible person
Point 2 – Announce officially → Nonofficial 5S activities are not spread.
Point 3 – Execution by all member → Everybody must participate.
Point 4 – Be clear purpose
Point 5 – Execute patiently → Do not feel annoyed and do sincerely
Point 6 – Top mgmt. checks the 5S activity directly.
Point 7 – 5S activities are the stepping-stone of company survival. → There is no improvement that do not go through 5S
activity.
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3. Fixation Point3. Fixation Point
13
5S is the positive attitude of Yes!
1. Throw away a fixed idea
2. Think about becoming method
3. Analyze the actual condition instead of excuse
4. Wrong thing repairs immediately
5. Improvement which does not need money executes first.
6. Make do when urgent
7. The improvement is infinite
8. Ten people's wisdom than knowledge of one person
9. Pursue a fundamental cause and repeat “why” 5 times
10. Don't pursue perfection. Just try!
The motive power of 5S is the spirit which changes negative
mind into positive attitude
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3. Fixation Point3. Fixation Point
14
Sort
Shine
Set In
Order
Standardiz
e
[ Method ]
Sustain
[ Goal ]
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4. Expectation effect(Out put)4. Expectation effect(Out put)
15
5S Effect Effect 1 – 『 Waste ZERO 』 : Cost saving and efficiency
improvement * Remove wasted motion for searching, transporting etc. * Reduce wasted space. * Overstocking is avoided. (Warehouse, shelf, cabinet etc.)
Effect 2 – 『 Accident ZERO 』 : Safety improvement * Cleaned machine and equipment can be notified hazardous
factor
* The storage place of the material comes to be clear
* Prevent collapse of products.
Effect 3 – 『 Breakdown ZERO 』 : Maintenance improvement * The garbage, dirtiness, dust shorten life of equipment
remarkably. * Prevent oil leakage and deal with a problem in advance.
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4. Expectation effect(Out put)4. Expectation effect(Out put)
16
Effect 4 – 『 Defect ZERO 』 : Quality improvement * It is difficult to find failure in dirty workplace. * Can use the right parts in the right place.(3R) * Right storage of inspection & measuring instrument is critical.
Effect 5 – 『 Change over ZERO 』 : Be Multi products, productivity improvement
* Reduce wasted time looking for parts or tools. * The clean workplace improves a efficiency. * Arrangement of measuring tool can do preliminary preparations. Effect 6 – 『 Delay ZERO 』 : On-time Delivery Effect 7 - 『 Dissatisfaction ZERO 』 : Enterprise development * The trust becomes larger little by little. * The customer is satisfied.
Kortek Let’s Win Customers
4. Expectation effect(Out put)4. Expectation effect(Out put)
Remove all items from the workplace that are not needed for current operations. Leave only the bare essentials.
KEY POINT : Removal
Method - Targets : excess inventory, obsolete items, quality defects, unneeded tools/equipment - Use red tags, if necessary - Take before and after pictures
17
1) Sort /1) Sort /Sorting Sorting (SEIRI)(SEIRI)
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5. Details5. Details
19
Arrange needed items so that they are easy to find, use and put away.
KEY POINT : Everybody find easily
Method - Decide on appropriate locations - Consider how to store tools and jigs - Consider principles of motion waste - Visual controls
2) Set In Order /2) Set In Order /Systematic Arrangement Systematic Arrangement (SEITON)(SEITON)
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5. Details5. Details
20
Sweeping, wiping-off equipment, painting and assuring
everything stays clean.
KEY POINT : Check
Method - Decide cleaning objects - Decide person in charge for cleaning. - Decide cleaning method - Decide cleaning tool
3) Shine 3) Shine //CleanlinessCleanliness(SEISO)(SEISO)
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5. Details5. Details
21
Under the cleaning without dirt and garbage Keep the condition clean
KEY POINT : Identify the normal and abnormal condition easily
Method - Measuring tools are ready to use ? - Do every morning clean ? - Do arrange to end after work
4) Standardize /4) Standardize /MaintenanceMaintenance (SEIKETU)(SEIKETU)
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5. Details5. Details
22
Keep the procedure or role practice without realizing it.
KEY POINT : Mindset to follow the procedure is basic.
Method - Use/develop Check Sheet - Perform patrol check - Encourage training/participation - Offer rewards and recognition
5) Sustain /5) Sustain /Self Discipline Self Discipline (SITSUKE)(SITSUKE)
Kortek Let’s Win Customers
5. Details5. Details
23Dot line30
Yellow
Moving path indication of gate9
Circle50 pieYello
wChair position [each leg]8
100RedLoading line [Defect]7
100Yello
wLoading line [Inspection waiting]6
Solid line using right
angle
100BlueLoading line [inspection completion]5
" ㄱ“ Form30Yello
w work table, humidifier, garbage can, desk,
other location mark4
Avoid right angle
100Yello
wBoundary line (corner)3
Dot line100Yello
w
Boundary line (entrance) The line where the hand car, cart goes in
and out indicates a dot line [place where a person goes in and out indicates a solid
line]
2
Solid line100Yello
wBoundary line (passage)1
ExampleFormWidthColorName 100mm
150mm 150mm 150mm
50mm
100mm
100mm
Diameter 50mm
50mm 50mm 50mm
50mm
100mm
100mm
100mm
■ Boundary line standard
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8. Standard & 8. Standard &
exampleexample
24
■ Work in process (WIP) storage
Item Purpose
Purpose
Subject
Standard
- In order to distinguish easily.
- WIP- Various TEST products etc.
- Horizontal writing is principle.- Indicate the type of products- Use the yellow writing on yellow Line- The distance of products line keeps away over 10mm.- Line width : 100mm- The distance between Pallets : 50mm.
Diagrammati
c
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8. Standard & 8. Standard &
exampleexample
25
■ Transportation machinery mark
Item Purpose
Purpose
Subject
Standard
-Assign the storage area and responsibility in order to control repair, loss etc. easily.
- Cart, forklift truck, electromotive etc.
- Place left side, top area of transportation- If sticking is hard, place it seeing well - The place where the attachment is difficult fastens with string.- Put the line on floor with yellow line 50mm
Diagramma
tic Kortek Let’s Win Customers
8. Standard & 8. Standard &
exampleexample
26
■ Forklift truck storage method
Item Purpose
Purpose
Subject
Standard
- In order to do right position control
- forklift truck, electromotive etc.
- Separate Line and the outer wall of products does with 50mm.- Line marking does with a solid line.- Line color does with the yellow.- The right location mark width does with 50 mm.- Attach the name of designation place.
Diagramma
tic
Kortek Let’s Win Customers
8. Standard & 8. Standard &
exampleexample
27
■ Tool mark method
Item Purpose
Purpose
Subject
Standard
- In order to use easily.
- Tools etc.
- Indicate the line same as tool shape. And easy to hold the tool. - Place the tool information just above the tool and put the nameplate of user on the right side of tool box. - Nameplate of user indicates the destination of the tools in order to find easily.- The frequent using tool moves with SET units.
Diagrammati
c
Kortek Let’s Win Customers
8. Standard & 8. Standard &
exampleexample
28
A Max quantity mark
Min quantity mark
Item mark
Place mark
Location No.
<Parts signboard> <Parts RACK signboard>< Auxiliary equipment signboard>
■ Control example
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8. Standard & 8. Standard &
exampleexample
29
<Example 1> < Example 2>
■ Direction mark
WallWorkplace
<Rotator direction mark> <Pipe fluidity direction mark> <Passage direction mark>
■ Tool arrangement
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8. Standard & 8. Standard &
exampleexample
30
<Equipment cleaning, painting>
< Safety mark(Tiger mark)>
<Work area painting>
■ Cleaning example
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8. Standard & 8. Standard &
exampleexample
WHAT U HAVE COME ACROSSWHAT U HAVE COME ACROSS AT THE END OF THIS TRAINNING. AT THE END OF THIS TRAINNING.
Followings can be possible from the 5S
1. NEAT & CLEAN WORKPLACE
2. SMOOTH WORKING
3. NO OBSTRUCTION
4. SAFETY INCREASES
5. PRODUCTIVITY IMPROVES
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Cont.Cont.
6. QUALITY IMPROVES
7. WASTAGE DECREASE
8. MACHINE MAINTENANCE
9. VISUAL CONTROL SYSTEM
10. EMPLOYEES MOTIVATED
11. WORKSTATIONS BECOME SPACIOUS
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Thank YouThank You
Kortek Let’s Win Customers
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