5 s Study Material

8/6/2019 5 s Study Material

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1. What is 5 'S ?2. Why 5 'S ?3. Who is to practice 5 'S ?4. When and Where 5 'S' can be used ?5. How to practice 5 'S ?6. 5 'S' - A Foundation for TQM7. 5 'S' in ISO 9001 : 2000

CONTENTS

5 S An Awareness


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1. WHA T I S 5 S ?

5S Philosophy focuses on effective work placeorganization and standardized work procedures.

5S simplifies your work environment, reduceswaste and non-value activity while improving

quality efficiency and safety.

Contd.

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1. WHA T I S 5 S ? Contd .

Step 1 - SORTRed TagSort Out Throw Out!

Step 2 - SET I N ORDERWhat goes where?Set Limits

Arrange close to hand

Step 5 - SUST AI NWork to StandardsMonitor progress

Continuous Improvement

P

D

C

Step 4 - ST AND ARD I SEStandardise activityMake steps 1,2 & 3 a habit Share Information

Step 3 - SHI NEEliminate dirt, dust, oil & scrapEnsure everywhere Shines!

A

Contd.

5 S An Awareness


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1. 1 1 s t S SE I RI - SORT

Stratification management and dealing with the causes.1. Throw out the things you do not need.

2. Free up valuable floor space

3. Eliminate such things as broken tools, obsolete jigsand fixtures, scrap and excess raw material.

4. Prevent the JIC job mentality (Just In Case.)

5. Number of necessary items in the workplace must bekept to its absolute minimum.

6. Simplification of tasks, effective use of space, andcareful purchase of items follow.

Contd.

5 S An Awareness


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Simple Sort Matrix

PR I OR I TY FREQUENCY OF USE HOW TO STORE

LOW Less than once a year Throw away

Store in distant place

AV ER AG E Once every 2 6 monthsOnce a monthOnce a week

Store togetherSomewhere infactory

HIGH Once a dayOnce an hour

Carry or keep at individual workplace

1. 1 1 s t S SE I RI SORT Contd .5 S An Awareness


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1. 2 2 nd S SE I TON - OR GANIZ E

Focuses on efficient and effective storagemethods.

What do I need to do my job?

Where should I locate this item?How many of this item do I need?

how fast you can put items away and

retrieve them in time of need

Contd.

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Functional storage and eliminating the need to look for things

1. Everything has a clearly designed place .

2. Thirty-second storage and retrieval

3. Filing standards

4. Zoning and placement marks

5. Eliminate lids and locks

6. First in, first out.

7. Neat notice boards

8. Easy-to-read notices

9. Straight lines and right angles

10. Functional placement for materials, par carts, shelves, tools, equipments,and everything else

11. Organize the warehouse

1. 2 2 nd S SE I TON OR GANIZ E Contd .5 S An Awareness


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C leaning as inspection and degree of cleanlinessQuick 5S drills

Individual responsibility

Make cleaning and inspection easier

Sparkling clean campaignsEverybody is a janitor (priority 5S)

Perform cleaning inspections and correct minor problemsC lean even the places most people do not notice

Deal with the causes of dirt and leaks

Housecleaning

Inspect covers and troughs to prevent leakage and setterC lean the grounds

Eliminate grime and burrs

Eliminate oil pans

1. 3 3 rd S SE I SO - CLE AN5 S An Awareness


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Visual management and 5S standardization. Both personal & environmental

cleanliness1. Okay marks

2. Danger zones marked on meters

3. Thermal labels

4. Directional markings

5. Belt-size labels

6. Open-and-shut directional labels

7. Voltage labels

8. Color-coded pipes

9. Oil labels

10. Warning colors

11. Fire extinguisher signs

12. Fool proofing

13. Responsibility labels

14. Wire management

15. Inspection marks

16. Precision-maintenancelabels

17. Limit labels

18. Color coding

19. Transparency

1. 4 4 th S SE IK ETSU - ST AND ARD I SE5 S An Awareness


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'Discipline. ' Clear responsibility.Commitment to maintain orderliness.

Practice the first 4 S as a way of life.Elimination of bad habits and constant practiceof good ones.True shitsuke - personnel voluntarily observecleanliness and orderliness at all times, withouthaving to be reminded by management.

1. 5 5 th S SHI TSU KE SELF DI SC I PLI NE5 S An Awareness


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2. WH Y 5 S ? Contd .

Before 5 S

After 5 S -C leaned,organized and drawerslabeled (less time andfrustration hunting)

5 S An Awareness

EX AMP

LES


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3. W ho is to prac t ic e 5 S ?

CEO should lead the practice

Participation by everybody

5S practice should be self sustaining

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4. W hen & W he re 5 S s hould b e u s ed

All the time

Literally everywhere

Application of 5S

this can be applied anywhere,Site, Offices,Workshop,Stores?

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1 . Observe/interview/evaluate2. Establish a quarantine area3. Initiate the red tag process4. Review the summary sheet with associates

5. Determine additional resource needs6. Clean up entire project area7. Conduct another observation8. Evaluate area using the checklist criteria

9. Root cause analysis/establish countermeasures10 . Repeat steps 6 - 8 to improve score11 . Post evaluation on visual performance board1 2. Determine review cycle

5. H OW TO PR ACTI CE 5 ' S ? contd,5 S An Awareness

Contd.


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5 S An Awareness

5. H OW TO PR ACTI CE 5 ' S ? contd,

Contd.

Dept. Owner Co-ordinatorPrevious Today

DateMark

Score Board ( Check List )5 S in Office

Marks5 S No. Checking Item Evalua tion Criteria 0 1 2 3 4

C L E A R I N G

U P

O R G A N I Z I N G

C L E A N I N G

S T A N D A R D

I Z I N G

S E L F D I S C I P L I N E

S CORE BOARD


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5 S An Awareness

5. H OW TO PR ACTI CE 5 ' S ? contd,

ST AT S O 5 S IN O I CE

Unit / De t ./ Sec tion Position As On

Own e U nit Coordinator

S S S S S 1 S

SEIRI 2 S

SEITON 3 S

SEISO4 S

SEIKETSU 5 S

SHITSUKE


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6 . 5 S A Found a t ion fo r TQM

TQM is a philosophy and takes about a decade for a

traditional organization to demonstrate the destination

less journey.

The journey starts with a clarity on why are we? where

are we? And Where do we want to go? The practice of

5 S in true spirit evidences the response to above

queries.

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7 . 5 S & I SO 9001 : 2000The QMS of ISO 9001:2000 is based on 8 QM Principles like

1. Customer focus2. Involvement of people3. System approach to management 4. Factual approach to decision making5. Leadership6. Process approach7. Continual Improvement 8. Mutual beneficial Supplier relationship

To mention a few Specific relation

4.2.3 & 4.2.4 Control of records - Seiri6.4 Work Environment - Seiton7.5.3 Identification and Traceability - Seiso7.5.5 Preservation of Product - Sheiketsu8.5.1 Continual Improvement - Shitsuke

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Let's leave the last word to Hiroyuki Hirano, author of 5 S -

Five Pillars of the Visual Workplace:

"A company that cannot successfully implement the 5 S s

cannot expect to effectively integrate JIT, re-engineering, orany other large-scale change. Good workplaces develop

beginning with the 5 S's. Bad workplaces fall apart

beginning with the 5 S s."

5 S An Awareness

HI ROYU KI HI R ANO S MESS AG E


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R ecap

1. What is 5 'S ?2. Why 5 'S ?

3. Who is to practice 5 'S ?4. When and Where 5 'S' can be used ?5. How to practice 5 'S ?6. 5 'S' - A Foundation for TQM7. 5 'S' in ISO 9001 : 2000

5 S An Awareness

Documents

5 s Study Material