5s - basic training what is 5s and why do we want to do it? alok sharma 22\06\2010
TRANSCRIPT
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5S - BASIC TRAINING
What is 5S and why do we want to do it?
ALOK SHARMA 22\06\2010
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• Seiri – Sort (housekeeping)
• Seiton – Systematic Arrangement
(workplace organization)
• Seiso – Shine (Cleanup)
• Seiketsu – Standardize
• Shitsuke – Sustain (Self Discipline)
What is 5S ?
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What is 5S ?
5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems).
These are foundational to Kaizen (continuous improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts.
5S is one of the activities that will help ensure any company’s survival.
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5S
1. Sort - All unneeded tools, parts and supplies are removed from the area
2. Set in Order - A place for everything and everything is in its place
3. Shine - The area is cleaned as the work is performed 4. Standardize - Cleaning and identification methods are
consistently applied 5. Sustain - 5S is a habit and is continually improved Also - Work areas are safe and free of hazardous or
dangerous conditions
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Some New Words
Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes
Some Japanese words one need to know: Kaizen-(pronounced “kai zen”) – Continual improvement
Muda-(pronounced “moo da”) - waste
Gemba-(pronounced “gim ba”) – workplace
Kanban-(pronounced “kon bon”) - Pull type inventory control system. Items are only produced to meet customer needs. The request to produce more is signaled from an upstream operation and/or customer orders.
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KAIZEN: What it is?
1) Process Improvement
2) Observation
3) Use of New Paradigms
4) Short Time
5) Zero Investment
6) Human Development & Empowerment
7) Profits & Savings - Plenty
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ALWAYS
CONTINUAL
CHANGE
GOOD
IMPROVEMENT
FOR THE BETTER
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KAIZEN IS A JOURNEY FROM:
EVENT
RESULT
GROSS
ENFORMENT OF CHANGE
TO CAUSE
TO PROCESS
TO MICRO
TO INDUCEMENT OF CHANGE
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KAIZEN IS CONTINUAL IMPROVEMENT
TIMETIMEIM
PRO
VE
ME
NT
IMPR
OV
EM
EN
T
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KAIZEN: KNOW THE REALITY THROUGH YOUR SENSE
OBSERVATION INTELLIGENCE
PHYSICAL EFFORT
PARADIGM OF HIGH PRODUCTIVITY & QUALITY
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KAIZEN AT GEMBA
GEMBA: PLACE OF WORK
GEMBA is where . . .
Value is added
Actual work is done to meet customer requirement
Problems are solved
Staff is responsible for providing support, not for giving instruction
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1. 5S Principles
Elimination of wasteElimination of waste Every body is involved, Every body is involved,
Co-operative effortCo-operative effort Attack root causeAttack root cause Human being is not Human being is not
infallibleinfallible
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2. Objectives
Improve housekeepingImprove housekeeping Make every individual Make every individual
responsible for responsible for housekeepinghousekeeping
Beautify by simple meansBeautify by simple means Productivity improvement Productivity improvement
by saving time, space etc.by saving time, space etc.
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The ‘S’ Japanese Word What is involved Objective
1SSEIRI
(Sorting Out)
Segregate necessary from unnecessary
Remove what is not required
Decide on frequency of sorting
Saving and recovering Space
2SSEITON
(Systematic Arrangement)
Arranging in order
Place for everything, Everything in its place
Minimizing search time
3SSEISO
(spic and Span)
Cleaning the work place/ equipment
Attaining the warning bell
Inspecting for problems
Taking corrective actions faster
4SSEIKETSU
(Standardization)
Working Methodology
(Procedures & WI)
Achieving higher productivity and better quality
5SSHITSUKE
(Self Discipline)Forming the habit in form of Training and Discipline
Doing it right at First Time
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SEIRI = SEIRI = SortingSortingSEIRI = SEIRI = SortingSorting
Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary
items
Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary
items
Activity Establish a criteria for eliminating unwanted itemsEliminate unwanted items either by disposing
them or by relocating them.
Success Area saved or percentage of space available
Indicator
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SEIRI = SEIRI = SortingSortingSEIRI = SEIRI = SortingSorting
Japanese Meaning :
The Japanese meaning of “Seiri” is
to straighten and contain.
- Get rid of waste and put it in order according to rules
Japanese Meaning :
The Japanese meaning of “Seiri” is
to straighten and contain.
- Get rid of waste and put it in order according to rules
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1 ‘S’ – Our respiratory system sorts oxygen and other gases. And exhales other gases which are unwanted for our body
1 ‘S’ - SEIRI
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Sort for . . .
Not Needed at All
Needed but not Now
Needed but not here
Needed but not so much Quantity
1 ‘ S’
WANTED UNWANTED
1S – SEIRI : SORTING
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1. Item is not needed
2. Item is needed however quantity in stock is more than what is needed for consumption in near future
3. Contingency Parts
Critically decide the quantity of contingency parts to be retained and criteria for such parts
Seiri = SortingSeiri = Sorting What is unnecessary
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Frequency of use Storage Method
*Things you have not used in the past one year
Throw them out
*Things you have used once in the last 6-12 months
Store at distance OR Keep in store
LOW
*Things you have used only once in the last 2-6 months
Store it in central place in your zone
*Things used more than once a month
Store it in central place in your zoneAV
ERAG
E
HIGH *Things used once a week Store near the workplace
*Things used daily or hourly Store near the workplace
Organization
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Seiri = SortingSeiri = Sorting Identifying unnecessary
1. Parts & Work in Process (WIP)• Things fallen back behind the machine or rolled under it• Broken items inside the machine• Things under the racks/ platform• Extra WIP• Stock of rejected items• Items accumulated over period for rework• Material awaiting disposal decision• Material brought for some trial, still lying even after trial• Small qty of material no longer in use
Contd..
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Seiri = SortingSeiri = Sorting Identifying unnecessary
2. Tools, Tooling, Measuring devices• Old jigs, tools not in use are lying• Modified tools, tooling for trial, are lying after trial• Worn out items like bushes, liners, toggles etc. lying• Broken tools, bits, etc. may be lying• Measuring equipment not required for the operation being performed , is lying3. Contingency Parts• Many times storage place for contingency parts become a last refuge for broken parts, surplus items and things nobody is likely to use
Contd..
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Seiri = SortingSeiri = Sorting Identifying unnecessary
4. Shelves and Lockers• Shelves and lockers tends to collect things that nobody ever uses , like surplus, broken items etc.5. Passages and Corners• Dust, material not required seem to gather in corner6. Besides Pillars and under the stairs• These places tends to collect junk, spittoon etc.7. Walls and Bulletin Boards• Old out dated notices which have lost their relevance• Posters or bulletins on wall• Dust, remains of torn notices, cell tape pieces
Contd..
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Seiri = SortingSeiri = Sorting Identifying unnecessary
8.Floor, Pits, Partitions• Defective parts• Protection caps, covers• Packing material• Hardware items , small items• Even tools, toolingItems dropped on the floor are never picked9.Computer Hard Disk• Many unwanted, outdated, temporary files pile up
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Seiri = SortingSeiri = Sorting Improvement methods
1. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system e.g. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for systeme.g. How to perform Seiri (sorting)
3. Check ListA check sheet is used to decide what sort of main systemand sub system are necessary.
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Seiri = SortingSeiri = Sorting Dealing with papers
How to Reduce Papers on Your Table ?
1. Make a single pile of papers2. Go through them and sort in following categories
a) Immediate actionb) Low priorityc) Pendingd) Reading materiale) For information
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Seiri = SortingSeiri = Sorting Dealing with papers
How to Reduce Papers on Your Table ?
4 D Principle4 D Principle
DO DELEGATE DELAY DUMP
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2 ‘S’
Seiton : Systematic Arrangement
Arranging things in systematic way
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2 ‘S’ – In our body there is a fixed place for every organ.
2 ‘ S’ - SEITON
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SEITION = SEITION = Systematic ArrangementSystematic ArrangementSEITION = SEITION = Systematic ArrangementSystematic Arrangement
Meaning To determine type of storage and layout that will ensure easy accessibility for everyone .
Meaning To determine type of storage and layout that will ensure easy accessibility for everyone .
Activity - Functional storage - Creating place for everything and putting everything in its place
Success - Time saved in searching
Indicator - Time saved in material handling
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SEITION = SEITION = Systematic ArrangementSystematic ArrangementSEITION = SEITION = Systematic ArrangementSystematic Arrangement
Japanese Meaning:
Dictionary meaning of Seiton is “to be correctly
prepared” and “to prepare correctly”.
In short these means : (a) arrange correctly in accordance with the correct method of
doing activities and
(b) make thorough preparations so that activities can be done even if they occur abruptly
Japanese Meaning:
Dictionary meaning of Seiton is “to be correctly
prepared” and “to prepare correctly”.
In short these means : (a) arrange correctly in accordance with the correct method of
doing activities and
(b) make thorough preparations so that activities can be done even if they occur abruptly
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Seiton = Systematic ArrangementSeiton = Systematic Arrangement
How to achieve Systematic Arrangement ?
• Decide where things belongDecide where things belong
• Decide how things should be put awayDecide how things should be put away
• Obey the Put away rulesObey the Put away rules
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Seiton = Systematic ArrangementSeiton = Systematic Arrangement
How to achieve Systematic Arrangement ?• Decide where things belong - - Standardize Nomenclature - Determine an analytical method of storage• Decide how things should be put away - Name & locations to everything. - Label both item and location - Store material functionally - Prevent mistakes with coding by shapes & colour contd..contd..
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Seiton = Systematic ArrangementSeiton = Systematic Arrangement
How to achieve Systematic Arrangement ?• Decide how things should be put away - - Follow (FIFO) first in first out rule - If two identical items are to be located, then store them separately, - colour code them.
• Obey the rules - - Put the things back to their location after their use
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Seiton = Systematic ArrangementSeiton = Systematic Arrangement
USE :USE :
1 ) Signboards1 ) Signboards
2) Colour codes2) Colour codes
3) Outline markings3) Outline markings
4) Labels4) Labels
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Seiton = Systematic ArrangementSeiton = Systematic Arrangement
UsageFrequency
• Store frequently used material near the workplace and less frequently at some distance
Weight &Shape of theMaterial
• Heavy material should be stored at lower levels/layers Place directly on the material handling device for ease of handling
Functional Storage
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Seiton = Systematic ArrangementSeiton = Systematic Arrangement
Category• Same category of material may be stored in one location. e.g, Allen Screws, Oil Seals Operation
Wise
• All items required for an operation may be stored in one location. e.g, Allen key, spanner etc hand tools required for setting m/c
Functional Storage
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Seiton = Systematic ArrangementSeiton = Systematic Arrangement
• Outlining and Placement Marks - - Mark boundaries of dept., aisles, Machines - Follow straight line, right angle rule - Nothing shall be kept outside the boundaries• Stands and shelves - - Keep only required number of stands and shelves - Standardize height, size - Provide casters where necessary so that it can be moved
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Seiton = Systematic ArrangementSeiton = Systematic Arrangement
• Wires and Ducts - - Colour code - When there are multiple connections – bundle the wires, label them and make sure that they are in straight line /right angle and firmly anchored.• Machine-tools & Tools - - Put the tools in the order you need them - Location of the tool should be such that it can be put away with one hand - Try to eliminate some hand tools by permanently attaching it to the bolt head
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Seiton = Systematic ArrangementSeiton = Systematic Arrangement
• Blades, Dies, Other important consumables - - Store them in the protected place - Maintain these things regularly by applying rust preventive, oiling etc.• WIP- Work In Process - - Designate a place for each component/part - Decide on how much quantity to be stored - Ensure that there is no damage to good part during transit, they do not get rusty and they are not mislabeled
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Seiton = Systematic ArrangementSeiton = Systematic Arrangement
• Oils - - Reduce number of oils used (Standardize) - Colour code for oil - Safety aspects - fire prevention, pollution, leak, spillage
• Instrumentation & Measuring Devices - - Label them, show direction of flow
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Before sort after sort
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Before sort after sort
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3 ‘S’Seiso : Cleaning
KIKEN KITSUI KITENOI
Clean the surroundings !
(DANGER) (PROBLEM) (DIRT)
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3 ‘ S’ - SEISO
3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc
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SEISO = SEISO = Cleaning Cleaning SEISO = SEISO = Cleaning Cleaning
Meaning Cleaning trash, filth, dust and other foreign
matter. Cleaning as a form of Inspection
Meaning Cleaning trash, filth, dust and other foreign
matter. Cleaning as a form of Inspection
Activity - Keep workplace spotlessly clean - Inspection while cleaning
- Finding minor problems with cleaning inspection
Success - Reduction in machine down time
Indicator - Reduction in no. of accidents
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SEISO = SEISO = Cleaning Cleaning SEISO = SEISO = Cleaning Cleaning
Japanese Meaning :
Dictionary meaning “to clean up” and
“getting rid of dirt and unclean items”
While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection
Japanese Meaning :
Dictionary meaning “to clean up” and
“getting rid of dirt and unclean items”
While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection
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Seiso = CleaningSeiso = Cleaning
• Here cleaning means more than just keepingHere cleaning means more than just keeping things clean. Cleaning should be viewed as athings clean. Cleaning should be viewed as a form of Visual Inspectionform of Visual Inspection
• Preventive measures should be taken to tacklePreventive measures should be taken to tackle problems of dust, grim, burrs, leakage etc.problems of dust, grim, burrs, leakage etc. Root cause of the problem should be identifiedRoot cause of the problem should be identified and it should be eliminatedand it should be eliminated
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Seiso = CleaningSeiso = Cleaning
5 Minutes Every day for cleaning5 Minutes Every day for cleaning
• Devote 5 minutes everyday for cleaning yourDevote 5 minutes everyday for cleaning your work areawork area
• Participation of everyone is requiredParticipation of everyone is required
• Attack hard to clean places regularlyAttack hard to clean places regularly
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Seiso = CleaningSeiso = Cleaning
SL.No CHECKLIST TICK
1 Check Floors are clean
2 Check Work areas are clean
3 Check walls are clean
4 Check Pillars and Ceiling are clean
5 Check Windows are clean
6 Check Rooms and Electrical lights are clean
EXAMPLE : PREPARE CHECKLIST FOR CLEANING
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Seiso = CleaningSeiso = Cleaning
Seiso CycleSeiso Cycle
• BEFORE WORK, CLEAN AND INSPECT THE MACHINERY TOOLS, JIGS & FIXTURES.
• BEGINNING OF WORK - DO TRIALS AND START UP
• DURING OPERATION - CLEAN, INSPECT, DISCOVER AND DEAL WITH ABNORMALITIES
• AFTER COMPLETION OF WORK - DISPOSE OFF AND GET RID OF UN-NECESSARY THINGS
• SEISO IS A PART OF GOOD WORKMANSHIP• SEISO IS AN IMPORTANT PRE-CURSOR WITH 5S
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Seiso = CleaningSeiso = Cleaning
Cleaning-Inspection points for mostCleaning-Inspection points for most
equipmentequipment
Cleaning Grime, clogging, dust balls, rust, leakage etc.
Oils No oil, Low oil, leakage, filter clogging,dirty oil, dirty or bent oil lines, cloggeddrainage, oil spillage, worn& torn portsetc.
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Seiso = CleaningSeiso = Cleaning
Cleaning-Inspection points for mostCleaning-Inspection points for most
equipmentequipment
Tightening Loose bolts, welding detachment,loose parts, vibration or bumpingnoise, friction
Heat Oil tanks, motors, heater, axles, controlpanels, washing/ cleaning water, bearing, wiring etc.
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Seiso = CleaningSeiso = Cleaning
Cleaning-Inspection points for mostCleaning-Inspection points for most
equipmentequipment
Breakage, Cracks
Breakage, cracks, dent on slidingparts, handle has come off, brokenswitches, wire joints come off, wiresare broken or crack, crack dial ofvarious pre. gauges, meters etc.
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Seiso = CleaningSeiso = Cleaning
Function wise Cleaning check list ofFunction wise Cleaning check list of equipmentequipment
Pneumatics
Hydraulics
Compressed Air lines, air valves, connections, meters, filters, reservoirs etc.
Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc.
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Seiso = CleaningSeiso = Cleaning
Function wise Cleaning check list ofFunction wise Cleaning check list of equipmentequipment
Mach. & Power Train
Electrical
Motor fan, fan belt, couplings,Joints, pulleys, chains, pump bearings etc.
Control panel, lamps, light, switch,sensors, wiring, ducts, fuses etc.
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Seiso = CleaningSeiso = Cleaning
Function wise Cleaning check list ofFunction wise Cleaning check list of equipmentequipment
Tooling
EquipmentSpecific
Tools, fixtures, gauges, dies,measuring instruments, etc.
Furnaces, rollers, chutes, CNC machines, etc.
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Before shine after shine
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Before shine after shine
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4 ‘S’
Seiketsu
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4 ‘S’ – In every human being the structure of fingers are same I.e. Standardised. If it is not so, then we call it is
abnormal.
4 ‘ S’ - SEIKETSU
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SEIKETSU = SEIKETSU = StandardizationStandardizationSEIKETSU = SEIKETSU = StandardizationStandardization
Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure)
Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure)
Activity - Innovative visual management- Colour coding- Early detection of problem and early action
Success Increase in 5S indicator
Indicator
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SEIKETSU = SEIKETSU = StandardizationStandardizationSEIKETSU = SEIKETSU = StandardizationStandardization
Japanese Meaning :
Dictionary meaning
“unsoiled things, purity and cleanliness”
Clean manners ,
Clean cloths, clean politician
It is the proof that 3 S’s are being faithfully
carried out.
Japanese Meaning :
Dictionary meaning
“unsoiled things, purity and cleanliness”
Clean manners ,
Clean cloths, clean politician
It is the proof that 3 S’s are being faithfully
carried out.
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SEIKETSU = SEIKETSU = StandardizationStandardizationSEIKETSU = SEIKETSU = StandardizationStandardization
Tools used for analysis :
MTTR : Mean Time To Repair \ Recover
MTBF : Mean Time Between Failures
OEE : Overall Equipment Efficiency
Tools used for analysis :
MTTR : Mean Time To Repair \ Recover
MTBF : Mean Time Between Failures
OEE : Overall Equipment Efficiency
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Seiketsu = StandardizationSeiketsu = StandardizationSeiketsu = StandardizationSeiketsu = Standardization
• Regularizing 5S activities so that abnormalities are revealed• Make it easy for everyone to identify the state of normal or abnormal condition
• For maintaining previous 3S, deploy visual management
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Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization
• It has been estimated by scientific study that 60% of all human activities starts with sight
• 5S is easy to do once. It is consistency that is difficult. That is why Visual Management is so important, so that everybody will know that there is some problem. Visual ManagementVisual Management
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Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization
What visual control communicates ?What visual control communicates ?
It grabs one or more of our senses in order to• Alert us to an abnormality• Help us recover quickly• Promote adherence and prevention• Enable successful self management
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Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization
Some methods for visual communicationSome methods for visual communication
Colour coding Use of Labels Danger alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators
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Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization
Some methods for visual communicationSome methods for visual communication
LabelsLabels Precision management labels Inspection labels Temperature labels Responsibility labels
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Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization
Points to remember in making visual Points to remember in making visual control toolscontrol tools1. Make them easy to see from distance2. Put the display on the things 3. Everyone can tell what is right and what is wrong4. Anybody can follow them and make necessary corrections easily5. Work place should look brighter & orderly
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Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization
Some everyday visual management Some everyday visual management examples examples
Traffic signal Zebra crossing In car - Petrol indicator - Speed indicator Direction arrows Electric danger sign etc.
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Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization Seiketsu = Standardization
Some visual communication signsSome visual communication signs
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5 ‘S’
Shitsuke
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ENSURE . . .
Procedure & Work Instruction are correct.
Standard are expressed in specific.
Visual Aids are used.
Train at all levels.
Work ethics for effective management.
Transparent & Discipline work culture.
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5 ‘S’ – Every human body has its standard process which they maintain.
5 ‘ S’ - SHITSUKE
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SHITSUKE = SHITSUKE = Self DisciplineSelf DisciplineSHITSUKE = SHITSUKE = Self DisciplineSelf Discipline
Meaning Every one sticks to the rule and makes it a habit
Meaning Every one sticks to the rule and makes it a habit
Activity - Participation of everyone in developing good habits
- Regular audits and aiming for higher level
Success High employee morale
Indicator Involvement of all people
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SHITSUKE = SHITSUKE = Self DisciplineSelf DisciplineSHITSUKE = SHITSUKE = Self DisciplineSelf Discipline
Japanese Meaning :
Dictionary meaning is
“learning of the manners”
“having manners, dressing neatly” OR
“training children for good customs”
Japanese Meaning :
Dictionary meaning is
“learning of the manners”
“having manners, dressing neatly” OR
“training children for good customs”
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SHITSUKE = SHITSUKE = Self DisciplineSelf DisciplineSHITSUKE = SHITSUKE = Self DisciplineSelf Discipline
Activities :
5S Committee
5S Training
5S Competition / evaluation
5S Month
Posters , Literature etc.
Activities :
5S Committee
5S Training
5S Competition / evaluation
5S Month
Posters , Literature etc.
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Shitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self Discipline
We need everyone to maintain 5SWe need everyone to maintain 5Sguidelines.guidelines.
To maintain DISCIPLINE, we needTo maintain DISCIPLINE, we needto practice and repeat until itto practice and repeat until itbecomes a way of life.becomes a way of life.
Discipline is the Core of 5SDiscipline is the Core of 5S
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Shitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self Discipline
Discipline means making a steadyDiscipline means making a steadyhabit of properly maintaining habit of properly maintaining correct procedurecorrect procedure.
Time and effort involved inTime and effort involved inestablishing proper arrangementestablishing proper arrangementand orderliness will be in vain if and orderliness will be in vain if we do not have discipline towe do not have discipline tomaintain it.maintain it.
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Shitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self DisciplineShitsuke = Self Discipline PledgePledge
It shall be my constant effort toIt shall be my constant effort to maintain my workplace in goodmaintain my workplace in good order byorder by
Assigning a place for everythingAssigning a place for everything & keeping everything in its place& keeping everything in its place
Sorting out unwanted materialSorting out unwanted material periodically & discarding themperiodically & discarding them
Keeping my work area neat &Keeping my work area neat & clean everydayclean everyday
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Organization• Departments into areas• Coordinators at department level• Coordinator at each area level• Training for all• Audit each area and make action
check list• Implement actions• Audit and evaluation on
continuous basis
ORGANIZATION
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Some 5S Examples
Before 5S
After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)
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5S Pictures
Before After
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5S Pictures
Before: Repair After
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5S Pictures
Before After
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The Good, Bad and the UglyFirst the Bad and the Ugly - Life Without 5S
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The Good
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THANK YOU