5s seminar master

8/8/2019 5s Seminar Master

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New Chemsearch5 S Seminar

NCHCorporation


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Dr. W. Edwards Deming was known as the father of the Japanese post-war

industrial revival and was regarded by many as the leading quality guru in the United

States.

He was invited to Japan at the end of World War II by Japanese industrial leaders

and engineers. They asked Dr. Deming how long it would take to shift the perception

of the world from the existing paradigm that Japan produced cheap, shoddy imitations

to one of producing innovative quality products.

For his efforts he was awarded the Second Order of the Sacred Treasure by the formerEmperor Hirohito.

History

Taken from the Leadership Institute at - http://www.lii.net/deming.html

Dr. Deming told the group that if they would follow his directions, they could

achieve the desired outcome in five years. Few of the leaders believed him.

As Dr. Deming told it, "They surprised me and did it in four years."

Japanese scientists and engineers named the famed Deming Prize after him. It is

bestowed on organizations that apply and achieve stringent quality-performance criteria.


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"We have learned to live in a world of mistakes and defective products as if they were

necessary to life. It is time to adopt a new philosophy in America."

Dr. Demings 14 Points

Improve every process

Break down barriers in departments

Eliminate exhortations

Eliminate arbitrary numerical targets

Permit pride of workmanship

Encourage education

Include everyone in the company to accomplish the

transformation

Communicate company purpose

Adapt to the new philosophy

Cease dependence on mass inspection

End lowest tender contracts

Drive out fear

Institute training on the job

Institute leadership

Taken from the Leadership Institute at - http://www.lii.net/deming.html


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ISO

9000ISO 14000

OHSA's

18000TPM/TPS HACCP RC GMP

Quality Environment Safety PlantManagement

Food Hygiene Chemical Pharmaceutical

Program Focuses On Commitment to Government,Society, Customers & Employees

Can only be accomplished ifquality people are in place.

5 S

Program

Positive work attitudes

Ideas/Suggestions

Small Group Activities Team Effort

Overview


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1.1. Focus you and your people onFocus you and your people on qualityqualityThe program will:The program will:

Enable you to implement Kaizen(Plan-Do-Check action cycle)

Teach you the 5S basic daily activities for your employees

2. Earn larger profits2. Earn larger profits The program will teach you how to eliminate losses which can

be turned into profit

New 5S Program Goals

Without quality people and procedures, anymanagement system will be ineffective.


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SEIRI / SORTSEIRI / SORT = Necessary actions should be separated fromUnnecessary. Unnecessary actions must be eliminated.

SEITON / STORESEITON / STORE= Items should be neatly stored in theirdesignated location.

SEISO / SCRUBSEISO / SCRUB = Workers should take pride in cleaning their area.

SEIKETSU / SHINESEIKETSU / SHINE = Workers and workshops should always

be maintained in a neat and clean condition.

SHITSUKE / SHOWSHITSUKE / SHOW = Train people to follow the 5S disciplines.

The 5 S Components


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Which factory is making a profit?

Dirty Factory Clean Factory

Ask yourself and your employees:

Which should come first, cleanliness or profit?

Cleanliness & Profit


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Gives Visitors a Good ImpressionCustomers, Neighbors, Applicants, ISO9000/14000 Auditors or Government Assessors.

Provides a Comfortable Working EnvironmentSafe and Healthy OHSAs 18000

Enables Quality Products to be Produced

No stains or contamination on products/packages. Gives a Hygienic Environment

Clean & Disinfected (HACCP, GMP)

Purpose of Cleanliness

Having a clean work-area or factory can be very important.


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Next: Examples of costly

losses that can occur inthe work place


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Losses from a dirty factory (1/7)

Leaking of Hydraulic OilPotential problems: Malfunctioning ofmachines, labor to refill lost oil and

dirty floors.

With a conservative estimate of tendrops leaked every 10 seconds in yourentire factory, 2,000 liters of oil will be

wasted each year.Poor lubrication managementleads to your hydraulicsystems malfunctioning.

Which in turn, can mean asudden shut down of the wholeproduction line.

Aside from the money lost, spilt oil will result in ahazardous work place and can be very harmful tothe environment by improper disposal


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Leaking of compressed airCan lead to malfunctioning

machinesWith a conservativeestimate of ten small

leaks, over 2,500 hoursover the course of a year,$7,000 dollars will be lost.

Aside from the money lost, leakycompressed air can lead to yourgenerators running overtime. This wastedpower takes its toll on the environmentover time. Also, if the leaks become toolarge, it can cause your machines to

malfunction and potentially injureemployees.


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Scale buildupCauses expensive equipment tohave a short life.

Aside from the money lost, scale dirt buildup

can cause harmful bacteria that is released inthe air affecting your employees andenvironment alike.


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Accidents in

Japan per year

*Deaths: 2,300

*Severe

Injuries: 170,000

*Plant Fires:

3,800 cases

Total Losses ofUS$300,000,000


This fire wascaused by a belt

conveyeroverheating.

The building burned for 48 hours andneighbors had to be evacuated for a week.

SafetySafety

ProblemsProblemsLabors Safety

Labors HealthFire Hazards

OHSAS 18001

Aside from the money lost, fires can fatally injureemployees and neighboring workers alike. The

typical dark black smoke produced by fire is veryharmful to the environment as well.


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At an automobile assembly line asudden production shut down can

mean losses of $10,000/hour

Dirty electrical boardsCan cause serious problems andcomplications with factory equipment,even leading to a plant shut down.

Aside from the money lost associated with a plantshutdown, dirty electrical boards do not last as longand can harm the environment if not disposed of

properly. Electrical components not working correctlycan potentially injure employees as well.


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Unhygienic EnvironmentCan lead to employees and

customers getting sickWithout a efficient HACCP Program inplace problems such as foodpoisoning, E. coli and exposure to

harmful chemicals can occur.

A quality HACCP program alsohelps distinguish where certainchemicals are used, avoidingany harm to the environmentthrough improper disposal.


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Dirty air can lead to employees getting

sick or even cases of Asthma

Poor cooling efficiency

Leads to energy loss. A dirty

coil with 0.25mm of dirt canequal up to 40% more on the

electric bill.

Before Cleaning

After Cleaning

Aside from the money lost on the electric bill, powerplant emissions of sulfur dioxide and nitrogen oxidesare responsible for around 30,000 premature deaths

per year. In comparison, drunk driving kills around17,000 people per year. (http://www.net.org/air/death.vtml)


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Broken Machines

Slows Business Down!


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What is TPM?What is TPM?

Make profit by eliminating

unnecessary costs or losses, andreducing hazards in the workplace.

TPM

- Productive maintenance derived from employees

working together as a group

Total Productive Maintenance


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Unnecessary Costs

= LOSSES!


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Next: The four most

common areas thatlosses come from


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Losses (1/4)

Production losses can be the result of shutdowns or slower production speeds

Machine performing onschedule

Slow machine

that needsrepair

Over the course of just one day (Eighthours) this means a loss of 2,400 parts.


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ISO 9000

Losses (2/4)

Defects with thequality of your

machines and/or

products can leadto seriousproblems


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SafetyIgnoring safety aroundthe work place canlead to:

Employee AccidentsEmployee Health Issues

Workplace Pollution

Fire Hazards

Losses (3/4)

ISO 14000

OHSAs 18000


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Energy losses are

everywhere in theworkplace. From

scale deposits addingto the electric bill to

the leaking ofcompressed air, youhave to monitor your

energy usagecarefully.

Losses (4/4)

ISO 14000


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Regular productive maintenance canerase all of these problems.

What causes losses

Production Speed

Product Defects

Safety

Wasted Energy

The main factors we focused on to avoid losses were:


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During cleaning of

your machines,you shouldinspect, check

and fix anyabnormalitiesyou find.

AutonomousMaintenance

Autonomous Maintenance

Clean & Inspect Yourself!

Check for any: Noises,Vibrations, Smells, Heat,Leaking, Smoke, Rust,Cracks or Loose Bolts,


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Could save the compressed

air consumption of:

12,000Nm3/hr to

9,000Nm3/hr

Giving electric bill savings of

US$15,000/ yearUS$15,000/ year

Detect air leaking

Fix the problem immediately

Clean & Check

Cleaning Brings Profit


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To clean is to inspectTo clean is to inspect

Inspection discovers abnormalitiesInspection discovers abnormalities

Abnormalities should be corrected beforeAbnormalities should be corrected before

any failures that would result in lossesany failures that would result in losses

No failures means no unnecessary costs,No failures means no unnecessary costs,which means more profitwhich means more profit

So,So, CleaningCleaningbrings profit.brings profit.

Cleaning Brings Profit


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No accidents since its launch in 1964.No accidents since its launch in 1964.

Well established maintenance program.Well established maintenance program.

NCHNCH is a contributing part of their successis a contributing part of their success..

SHINKANSEN & JR RailroadsSHINKANSEN & JR Railroads (Japanese Bullet Train)(Japanese Bullet Train)

Just one of the productsused by JR railroads, theoperator of the Shinkansen,is SS-100 with the 161 air

gun that cleans critical highvoltage electrical surfaces.

One of our clients


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Training Room

NCH Solution

Demo

NCH Maintenance Chemicals

NCH

Equipment

Chemsearch giving the 5 S seminar to

an independent company


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Solutions from NCH

General Cleanliness

Electronic MaintenanceAHU Maintenance

Water TreatmentDescaling of Heat

Exchanger

Drain / Grease Trap

Maintenance

HACCP / Hygiene Control

Insect Control

Wire Ropes Lubricant

Floor Maintenance

Parts Cleaning

Tools Maintenance

Patching & Repair

Vehicle Maintenance

Corrosion Control

Ground Care


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New Chemsearch

5 S Seminar

NCH

Corporation

5s seminar master

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