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Dr Aneek Gupta1
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eek Gu
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Dr An
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5STHE SECRET TO
JAPANESE SUCCESS
By Dr Aneek Gupta
Dr Aneek Gupta 12Dr An
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pta
� WHAT PROBLEMS DO U COMMONLY ENCOUNTER AT YOUR WORKPLACE
�HIGH ABSENTEEISM
�HIGH TURNOVER
�DEMOTIVATED EMPLOYEES
�DISORDERED/ CLUTTERED ENVIRONMENT
�MISTAKES/ERRORS
Dr Aneek Gupta 13Dr An
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�THE SOLUTION TO ALL THESE
PROBLEMS IS
5SDr Aneek Gupta 14Dr
Aneek
Gupta
5S
HOUSEKEEPING TECHNIQUE
PRODUCTIVITY AND SAFETY ENHANCEMENT TECHNIQUE
Dr Aneek Gupta 15Dr An
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IDEA BEHIND 5SIDEA BEHIND 5S
� IN ORDER TO ACHIEVE HIGH LEVELS OF QUALITY, SAFETY,AND PRODUCTIVITY, WORKERS MUST HAVE A CONDUCIVE WORKING ENVIRONMENT
Dr Aneek Gupta 16Dr An
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WHAT IS 5S?WHAT IS 5S?
�Developed by the Japanese
�Housekeeping System
�Helps Create a Better Working Environment
and a Consistently High Quality Process
Dr Aneek Gupta 17Dr An
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THE 5S PRINCIPLESTHE 5S PRINCIPLES
�SEIRI – Organisation/Sort out
�SEITON – Orderliness/Systemize
�SEISO – The Cleaning/Shining
�SEIKETSU – STANDARDIZE
�SHITSUKE - Sustain/Discipline
Dr Aneek Gupta 18Dr An
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DISCOVERY OF 5SDISCOVERY OF 5S
� Thirty years ago researchers started studying the secret of success of Japanese manufacturing companies
� 5S turned out to be the most impressive "secret"
� The factories were so well organized that abnormal situations were readily apparent
Dr Aneek Gupta 19Dr An
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DISCOVERY OF 5SDISCOVERY OF 5S
�Equipments were so clean and well maintained that any problem such as a loose bolt or leaking oil could be easily seen
�This passion of cleanliness and orderliness became a hallmark of Japanese organizations
Dr Aneek Gupta 20Dr An
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ADVANTAGES OF 5SADVANTAGES 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
Dr Aneek Gupta 21Dr An
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ADVANTAGES OF 5SADVANTAGES OF 5S
�A clean and tidy workplace leads to greater well
being and increased motivation
�Company image improves
Dr Aneek Gupta 22Dr An
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ADVANTAGES OF 5SADVANTAGES OF 5S
� Health and Safety is ensured
� Machine maintenance
� Quality
� Productivity
� Lean Manufacturing
Dr Aneek Gupta 23Dr An
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ADVANTAGES OF 5SADVANTAGES OF 5S
� RESULTS IN A PLACE EASIER TO MANAGE
� SMOOTH WORKING NO OBSTRUCTION
� NO DEVIATION, NO PROBLEMS
� B/C EVERYONE KNOWS WHERE THE THINGS ARE SPPOSEDF TO BE
Dr Aneek Gupta 24Dr An
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ADVANTAGES OF 5SADVANTAGES OF 5S
�TIME SAVING
�QUICK RETRIEVAL
�ACCIDENTS & MISTAKES MINIMIZED
� INCREASES SPACE
�CREATES WORKPLACE OWNERSHIP
Dr Aneek Gupta 25Dr An
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ADVANTAGES OF 5SADVANTAGES OF 5S
�FOUNDATION OF ALL QC TOOLS
�CONTINUOUS QUALITY IMPROVEMENT
� LEAN MANUFACTURING
�KINDERGARTEN OF QUALITY TOOLS & TECHNIQUES
Dr Aneek Gupta 26Dr An
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ADVANTAGES OF 5SADVANTAGES OF 5S
� VISUAL MANAGEMENT SYSTEM
� VISUAL CONTROL TO SEE THE ABNORMALITIES
� SIMPLE SIGNALS THAT PROVIDE AN UNDERSTANDING OF THE CONDITION( NORMAL/ ABNORMAL)
� A LOOK AT THE PROCESS REVEALS ITS DIRECTION (RIGHT/WRONG)
Dr Aneek Gupta 27Dr An
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Lean Production
�The latest incarnation of JIT
�Based on Toyota Production System.
�Waste elimination
�Widely used in automotive manufacturing & other repetitive mfg.
Dr Aneek Gupta 28Dr An
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It’s a mindset & commitment to achieve a totally waste-free operation that’s focused on your customer’s success… achieved by simplifying and continuously improving all processes
It’s the elimination of waste Everywhere –while adding customer value…
Dr Aneek Gupta 29Dr An
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Lean production cuts costs & inventories rapidly to free cash, which is critical
It also supports growth by improving productivity & quality, reducing lead times, and freeing huge amounts of resources.
From the operations perspectiveFrom the operations perspective
Dr Aneek Gupta 30Dr An
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From the operations perspectiveFrom the operations perspective
For example, lean production frees office and plant space and increases capacity so companies can
1. Add product lines 2. In-source component production3. Increase output of existing products without
acquiring new facilities.
Dr Aneek Gupta 31Dr An
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KINERGARTEN OF ALL THE QC TOOLSKINERGARTEN OF ALL THE QC TOOLS
�5S IS THE STARTING POINT OF ALL THE QC TOOLS
�COULD BE SAID AS THE PRE- REQUISITE OF ALL QC TOOLS
Dr Aneek Gupta 32Dr An
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METHODOLOGY OF 5S
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1. ORGANISATION(SEIRI)1. ORGANISATION(SEIRI)
� 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
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RED TAG TECHNIQUERED TAG TECHNIQUE
�GIVE STAFF RED LABELS
�ASK STAFF TO GO THROUGH EVERY ITEM IN THE WORK PLACE
�ASK IF NEEDED & THOSE THAT ARE NEEDED,IN WHAT QUANTITY
�NOT NEEDED RED TAG IT
�STORE IN THE RED TAG AREA
RED TAG
Dr Aneek Gupta 35Dr An
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For wavering itemsFor wavering items
�PLACE THE SUSPECTED ITEMS IN THE RED TAG AREA FOR ONE WEEK
�ALLOW THE STAFF TO REEVALUATE THE NEEDED ITEMS
�AT THE END OF WEEK THOSE WHO NEED ITEMS SHOULD BE RETURNED
REDTAG
Dr Aneek Gupta 36Dr An
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ORGANISATIONORGANISATION
PRIORITY FREQUENCY OF USE HOW TO USE
Low Less than once per year
Once per year
Throw away
Store away from the workplace
Avg. Once per month
Once per week
Store together but offline
High Once Per Day Locate at the workplace
Dr Aneek Gupta 37Dr An
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2. ORDERLINESS(SEITON)2. ORDERLINESS(SEITON)
�ONCE YOU HAVE ELIMINATED ALL THE UNNEEDED ITEMS
�NOW TURN TO THE LEFT OVER ITEMS
Dr Aneek Gupta 38Dr An
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ORDERLINESS(SEITON)ORDERLINESS(SEITON)
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”
Dr Aneek Gupta 39Dr An
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ORDERLINESS(SEITON)ORDERLINESS(SEITON)
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?
Dr Aneek Gupta 40Dr An
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3. SEISO (CLEAN/SHINE)3. SEISO (CLEAN/SHINE)
�Create a spotless workplace
� Identify and eliminate causes of dirt and grime – remove the need to clean
�Sweep, dust, polish and paint
Dr Aneek Gupta 41Dr An
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SEISO (CLEAN/SHINE)SEISO (CLEAN/SHINE)
� Divide areas into zones
� Define responsibilities for cleaning
� Tools and equipment must be owned by an individual
� Focus on removing the need to clean
Dr Aneek Gupta 42Dr An
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4. SEIKETSU (STANDARDISE)4. SEIKETSU (STANDARDISE)
� Generate a maintenance system for the first three
� 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
Dr Aneek Gupta 43Dr An
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5. SHITSUKE (SUSTAIN / DISCIPLINE)5. SHITSUKE (SUSTAIN / DISCIPLINE)
� Means inoculate courtesy & good habits
� Driving force behind all 5S
� Deming’s point number 1: Constancy of purpose
� Make it a way of life
� Part of health and safety
� Involve the whole workforce*
� Develop and keep good habits
Dr Aneek Gupta 44Dr An
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LITMUS TEST FOR 5SLITMUS TEST FOR 5S
� 30 SECOND RULE
�ONE MUST LOCATE THE ITEM WITH IN 30 SECOND IF 5S IS PROPERLY IMPLEMENTED
�ALSO APPLIES TO THE ELECTRONIC RECORDS
RETRIEVAL
Dr Aneek Gupta 45Dr An
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WHAT U HAVE COME ACROSSWHAT U HAVE COME ACROSS
Followings Can Be Harnessed Form The 5S1. Neat & Clean Workplace
2. Smooth Working
3. No Obstruction
4. Safety Increases
5. Productivity Improves
6. Quality Improves
7. Wastage Decrease
8. Machine Maintenance
9. Visual Control System
10. Employees Motivated
11. Workstations Become Spacious Dr Aneek Gupta 46Dr An
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ThanksDr Aneek Gupta
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Dr An
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