MEL751: 5-S

This is a part of a course on “Industrial Engineering & Systems”

Good Housekeeping (5-S) A place for everything

Everything in its place

Everything Visible

Everyone involved in cleaning, checking & anticipating Problems

Philosophy of 5-S Based on Japanese words that

begin with ‘S’, the 5S Philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies work environment, reduces waste and non-value activity while improving quality efficiency and safety

5-S : Housekeeping Practices Sort means to separate needed tools, parts, and

instructions from unneeded materials and to remove the latter.

Systematize means to neatly arrange and identify parts and tools for ease of use.

Sweep means to conduct a cleanup campaign. Standardize means to conduct Sort, Simplify, and

Scrub at frequent, indeed daily, intervals to maintain a workplace in perfect condition

Self-discipline means to form the habit of always following the first four Ss.

Observations.. Once fully implemented, the 5S process

can increase morale, create positive impressions on

customers, and increase efficiency and organization. Not only will employees feel better about

where they work, the effect on continuous improvement can lead to less waste, better quality and faster lead times. Any of which will make your organization more profitable and competitive in the market place.

JAPANESE ENGLISH MEANINGTYPICAL

EXAMPLE

Seiri Sort OrganizationThrow away

rubbish

Seiton Systematize Neatness30-second retrieval of document

Seiso Sweep CleaningIndividual cleaning

responsibility

Seiketsu StandardizeStandardizati

onTransparency of

storage

ShitsukeSelf-

disciplineDiscipline

Do 5 “S” daily

5-S• SEIRI

- Identifying Unnecessaries ,Getting Rid of the Unnecessary , and Stratification Management

• SEITON - Functional Layout ; Deciding Where to Put What? - Promoting Neatness • SEISO - Workplace and Equipment Cleaning - The “To Clean is to Inspect” Attitude • SEIKETSU - Visual Management and and Tools and Methods for Visual Control • SHITSUKE - Habit Formation and Discipline , and Personal Responsibility

5S Examples - Standardize

4. Standardize - Cleaning and identification methods are consistently applied

Departments have weekly 5S tours

Every job has duties that use Sort, Set in Order and Shine

We all have common duties to do our part to keep all areas of the plant in shape - breakroom, restrooms, locker area, parking lot, etc

Dust bin spil led over !!Which principle of 5-S is violated here?

5S Examples - Sustain

5. Sustain - 5S is a habit and is continually improved

5S is a simple concept with powerful results.

.

the more we do 5S the better the work environment becomes: cleaner, safer, more organized, the work is easier, less confusion and less stress.

Bad and the Ugly

Give examples from your daily life of Bad and ugly :

Hostel, Hospital, Railway Station, airport etc.

Your own hostel room or your residence !

The Good Now give examples of Good ! What is the basic concept? How is it followed?

What is Waste (Muda)? Some of the main forms of waste are:OverproductionWaiting for materials, machines, or instructionTransportation or movementExcessive inventoryInefficient machine processing and/or operationProducing defectsPart or line changeover or machine setupInadequate housekeepingMiscommunication or inadequate instruction

Improvement (Kaizen) Principles

Get rid of all old (false) assumptions. Don't look for excuses, look for ways to make it happen . .“start NOW”! It does not cost money to do KAIZEN. If something is wrong “Fix it NOW”. Good ideas flow when we start questioning !!Ask "WHY" five times - get to the root cause. Look for wisdom from Ten people rather than one. Never stop doing KAIZEN.

Visual Controls - Andon Inidcators for tools, parts, and

production activities Placed in plain sight of all workers so

everyone can understand status of system at a glance

If a machine goes down, or a part is defective or delayed, immediate action can be taken

5-S on Youtube https://www.youtube.com/watch?

v=f2HB4YMipcw Learn how to apply 5-S https://www.youtube.com/watch?v=c0Q-

xaYior0 How 5-s fron office to factory (lean

principles) https://www.youtube.com/watch?

v=BqIOnpJ_crI

Benefits of 5S Reduce waste hidden Improve quality and safety Reduce lead time and cost Increase profit

Summary5-S is for every organizationClean-up and organize work area every day so that each new day is easier and safer than the day before

Take a good look around...Imagine zero waste/zero confusion!

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Additional information Get exposure to Initiatives of QCFI

(Quality Circle Forum of India) on 5-S

http://www.qcfi.in/mainhtml/5s.html