5s awarness training program

Prepared By – Mr. Deepak Kumar Sahoo

AWARNESS TRAINING PROGRAM

Prepared and Presented by :-

Mr. Deepak Kumar Sahoo , TPM Consultant

5S

Basic pillar to implement

- TPM – RCM – WCM – Lean Manufacturing -

Prepared By – Mr. Deepak Kumar Sahoo

5S - A new way of thinking for change ?

Think of the rocks and boulders as barriers because they slow

down the water flow. 5S is the first step to eliminate these barriers.

Prepared By – Mr. Deepak Kumar Sahoo

Observe the slide carefully . . .

Current Stage Transformation Future Stage

Prepared By – Mr. Deepak Kumar Sahoo

• 5S is short for: Sort, Set, Shine, Standardize and

Sustain

• 5S represents 5 disciplines for maintaining our work

place

• 5S is one of the activities that will help ensure our

company’s survival.

What is 5S and why do we want to do it?

5S is a systematic development process for creating a clean, safe and efficient workplace, where it is easy to do right.

Prepared By – Mr. Deepak Kumar Sahoo

Steps of 5S :-

1. Sort - Clear

2. Set - Orderliness

3. Shine – Clean and make it dust free

4. Standardize – Define & Refine

5. Sustain – Adherence

Prepared By – Mr. Deepak Kumar Sahoo

Benefit’s of 5S :-

5 S LEADS TO CLEAN & WELL ORGANIZED WORKPLACE

5 S LEADS TO BETTER SAFETY

5 S LEADS TO HIGHER EFFICIENCY

5 S LEADS TO BETTER QUALITY

5 S LEADS TO REDUCTION OF MACHINE BREAKDOWNS

SAFETY EFFICIENCY

QUALITYELIMINATING

BREAKDOWNS

5 S

Prepared By – Mr. Deepak Kumar Sahoo

Do not continue to live with temporary arrangements.

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5SSTEP BY STEP IMPLEMENTATION

NOTE : Before implementing SORT, please take photographs

of the various locations and make a note of the date.

The photographs “BEFORE” to be displayed

at that location.

Prepared By – Mr. Deepak Kumar Sahoo

UNIT :- Formaldehyde Plant Unit -4 Doc. No :- TPM/5S/B/A2/1004

Location :- Chemical Lab near SW corner Responsible Person :- Mr. R. Kulkarni

BEFORE 5S – (20.10.2010) AFTER 5S – (DD.MM.YYYY)

?COMMENTS :- The searching time was more. Chemical storage was not proper.

COMMENTS :-

5S activities . . .

Prepared By – Mr. Deepak Kumar Sahoo

Meaning

Distinguish between necessary and unnecessary items and

remove all items from the workplace that are not needed for

work place.(parts, tools, equipment, etc).

Activity

Establish a criteria for eliminating unwanted items.

Eliminate unwanted items either by disposing or by relocating.

Uses RED Tag.

Success

Area Save and getting spacious work place.

Reduce the Minor accident and better Spare part management.

SORT = Removal of unwanted items

Prepared By – Mr. Deepak Kumar Sahoo

Decide what you need and the

frequency of the tools use.

Remove unnecessary clutter tools,

gauges, materials etc.

Remove items which are broken,

unusable or only occasionally used.

Use Red Tag for disposal.

SORT : How we will approach

Prepared By – Mr. Deepak Kumar Sahoo

SORT : Putting Red Tags.

Prepared By – Mr. Deepak Kumar Sahoo

SORT : Examples

Prepared By – Mr. Deepak Kumar Sahoo

Meaning

To determine type of storage and layout that will ensure easy

accessibility for everyone.

Activity

Functional storage.

Shadow box, Marking.

30 Second rule

Creating place for everything and putting everything in its place.

Success

Time saved in searching

Time saved in material handling & Reduce MTTR.

SET = Systematic Arrangement

Prepared By – Mr. Deepak Kumar Sahoo

SET means we arrange items so they are easy to use, and labeling them so they are easy to find and put away.

It also means operating efficiency.

Compile LITMUS TEST.

What Does SET Mean?

LITMUS TEST

It is also known as 30 SECOND RULE. One must locate the items within 30 seconds.

Prepared By – Mr. Deepak Kumar Sahoo

Observe the tools carefully.

There are 16 tools.

Prepared By – Mr. Deepak Kumar Sahoo

Indicate the tools that are missing here ?

There are 14 tools : which 2 tools missing ?

Prepared By – Mr. Deepak Kumar Sahoo

Some more tools missing.

Prepared By – Mr. Deepak Kumar Sahoo

How we do in SET process ?

Paint brush 1

Paint brush 2

Drill M/C 1

Measuring tape

Spanner 2 Cutting wheelHammer

Torch

SawPlier

Drill M/C 2

Spanner 1

Vice

Screw driver

Plumber spanner

Horticulture tool

Prepared By – Mr. Deepak Kumar Sahoo

Easy Traceability :-

Paint brush 1

Paint brush 2

Drill M/C 1

Measuring tape

Spanner 2 Cutting wheelHammer

Torch

SawPlier

Drill M/C 2

Spanner 1

Vice

Screw driver

Plumber spanner

Horticulture tool

Prepared By – Mr. Deepak Kumar Sahoo

Examples of SET in Order. - 1 -

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Examples of SET in Order. - 2 -

Prepared By – Mr. Deepak Kumar Sahoo

Meaning

Cleaning trash, filth, dust and other foreign matter.

Identify and eliminate causes of dirt; find out the root cause.

Activity

Devote 5 minutes everyday for cleaning your work area

Keep workplace spotlessly clean

Inspection while cleaning

Finding minor problems with cleaning inspection

Success

Reduction in machine down time

Reduction in no. of accidents

SHINE = Cleaning For Inspection

Prepared By – Mr. Deepak Kumar Sahoo

SHINE means we sweep floors, scrub machines,

apply a fresh coat of paint, and then we keep

it that way.

Create a spotless workplace.

When you Sweep and Shine an area, inspect

machinery, equipment, and working conditions.

Devote 5 minutes everyday for cleaning

your work area

Find out the source of contamination.

Conduct root cause analysis to get the

sources and arrest.

How we will approach ?

Prepared By – Mr. Deepak Kumar Sahoo

Meaning

Setting up standards / Norms for a neat, clean, workplace and

details of how to maintain the norm (Procedure).

Activity

Innovative visual management.

CLTI (Cleaning, Lubrication, Tightening & Inspection) Checklist .

Color coding

Early detection of problem and early action

Success

Increase in 5S indicator & better fault finding.

Make things easier for operator.

STANDARDIZATION – Easy for work

Prepared By – Mr. Deepak Kumar Sahoo

Visual Control refers to the System of Exposing Deterioration or

Displaying the Status, just by making it Visible.

Salient features:

No need to Ask, Think or Walk to get the status

Deviation should Attract the Eye at a glance

Should be Unambiguous / Universal

What is Visual Control ?

HERHIS

Prepared By – Mr. Deepak Kumar Sahoo

Visual Controls in daily life

Prepared By – Mr. Deepak Kumar Sahoo

A visual factory makes it is easy to do right and difficult to do wrong...

Shadow boards

ON

SPZ 1600

Prepared By – Mr. Deepak Kumar Sahoo

Visual control in Office for Files.

FILES NOT IN ORDER

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Visual control Examples

Prepared By – Mr. Deepak Kumar Sahoo

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.

5S Training, 5S Competition / evaluation, 5S Posters ,

Literature etc.

Success

High employee morale Indicator.

Involvement of all people.

SUSTAIN = Self Discipline

Prepared By – Mr. Deepak Kumar Sahoo

UNIT :- Formaldehyde Plant Unit -4 Doc. No :- TPM/5S/B/A2/1004

Location :- Chemical Lab near SW corner Responsible Person :- Mr. R. Kulkarni

BEFORE 5S – (20.10.2010) AFTER 5S – (28.10.2010)

COMMENTS :- The searching time was more. Chemical storage was not proper.

COMMENTS :- Chemical searching time reduced to 25 seconds. All chemicals are properly marked. 5S Score – 85.7%.

5S : Before and After.

Prepared By – Mr. Deepak Kumar Sahoo

5S ENHANCE RELIABILITY.

Prepared By – Mr. Deepak Kumar Sahoo

Before and After photographs of 5S

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5S applied every where.

Prepared By – Mr. Deepak Kumar Sahoo

What is 5S ?

Steps of 5S ?

What we do during SORT process ?

What is LITMUS test ?

What are the benefits of 5S ?

What is visual control ?

Difference between STANDARDIZATION & SET ?

Why it is called 5S not 6S or 3S ?

Why we take photographs before 5S implementation ?

5S : All steps ?

5S Review