7Ws Elimination of Waste - Management Training

8/3/2019 7Ws Elimination of Waste - Management Training

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5/5/12

Whichfinger isimportant

?

S e l f

d i s c i p l i

n e

S e t i n

o r d e r

Shi

ne

S t a n d a r d

i z e

S o r

t

संकलन

सिुवधा

शिु चतव

सुि िशक

सू यवथ

SANKALAN

SUVIDHA

SUCHITWA

SUVYAVASTHI THA

SUSHIKSHI TH

1S

2S

3S

4S

5



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What is 5S ?

• An essential step required for Waste

Elimination• An integral step in Kaizen

• A required element to achieve Lean-

site Manufacturing.



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1SSort

2S

3S

4S 5

S

Set inorder

Shine

Standardi

ze

Self discipline



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Commitment

• If you are disciplined. :

– Rules will always be followed.

–

Laid down targets will be achieved. – Improvements will be promoted .

– The no. of defects will be reduced.

– The cost will not increase.

Your work area reflects yourpersonality.



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Advantages



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The Five Elements of 5S

•

Systematic Organization-Identifying what items are requiredand which are not.

•

Sorting Visual Placement- Itemsshould be easily retrievable, easy toget, and visual-easy to see.

•

Scrubbing Clean-Keep the area freefrom debris dirt oil items not



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rogress veEnhancements

•

Step 1 – Establish 5 S Implementation Team

•

Step 2 – Develop Specific Implementation Plan

•

Step 3



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Wastes

• Wastes are createdfrom

– Uncontrolled process

– Uncontrolled machines

– Uncontrolled inventory

–

Uncontrolled materials – Uncontrolled acts

– Uncontrolled thoughtsSo control is the key of wasteelimination



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9 Wastes

• Overproduction

• Delays (waiting time)

•

Transportation• Process

• Inventories

• Motions

• Defective products

•

Untapped Resources



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MUDA - the elimination of waste

• Waste is all around us.

• Like iceberg: Some of it is

visible, much of it is not.• Waste exists in many

forms –

•

waste materials by overordering,

• wrong ordering,

• obsolescence due to

unscheduled design changes



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Defects

• Defects:deviation fromspecification.

• Change fromQuality Controlto Quality

Assurance• QA: Efforts to

get the

process right,

Prevention

Pre ven tio

n

D e t e c t

i o n

QA is Prevention



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Over-Production

• Produce only the quantity required.

• This challenged the Economic Order

Quantity concept, which was builton

– acceptance of fixed ordering costs,

–

built around set-up times, – spread these fixed costs over large

batches.



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Waiting

• Time not being usedeffectively is a waste –

• we are incurring thecost of wages and allthe fixed costs of

– rent,

– rates,

– lighting and airconditioning

•



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Transporting

• Items being moved incur a cost

• Managing a factory with operationsspread apart is much more difficultthan when the subsequent stages areadjacent to one another.

• This can be seen as the primarymotive behind cellular manufacturing



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Movement

• People spending time moving aroundthe plant is equally wasteful.

– Time spend to fetch tools, drawing etc.

– Supervision

– Procuring spares from stores

•

Re design the plant layout andmaintain housekeeping so thateverything that is required aremaintained close to hand.



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Inappropriate Processing

• Re work, re process, reject

• Do only what is appropriate.



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Inventory

• Inventory need holding cost.

• Stock hides problems

•

Finding a problem is a good thing -now we can solve it, which wecouldn't until it came to light!



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Untapped & misusedresources

• Untapped Resources

• Misused Resources



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Some tips

• Clean up once you leave for the day.Make sure your trash isdisposed properly and is not a

hazard to others. This minimizes theamount of time needed to clean abigger mess.

• Try to maintain a clean work areathroughout the day. Take a fewminutes to sort out your paper work.

• Make sure that combustible and



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Some tips

• Make sure that all drawers andcabinet doors are closed properly.

This will prevent injury to yourself

and others.• Place tools in a safe and known area. That way you will be able to find it

again.• If you spot a spill, report it and make

sure its cleaned as soon as possible.

• If ou are not sure of the chemical



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• Get rid of all old (false) assumptions.• Don't look for excuses, look for ways

to make it happen• Don't worry about being perfect -

even if you only get it half right“start NOW”!

• It does not cost money to do KAIZENor 5S

• If something is wrong “Fix it Here&NOW”.

Improvement Principles



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Don’t be a weak link inour system

Do itDo it NowDo it RightNow

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7Ws Elimination of Waste - Management Training