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CHAPTER 5: PHASE WISE ROAD MAP OF 5S Purpose of the Chapter: To describe all the four phases of 5S in detail.

PHASE I: DEFINING AND TRAINING Formation of 5S Council: Objective: To enhance total participation of all levels of employees and develop a continuous improvement culture and best performance sprit in the teams. Typical 5S Organisation/ Council:

Typical Roles and Responsibilities of: 5S Champion:

1. Provides direction to the organisation 2. Approval of 5S vision, policy, objectives and KPI’s/ Reward policy.

5S Steering Committee:

Approval and verification 5S Management Programs. Approves changes in the key Procedures like Rewards, 5S Management Programs etc. Provides the bench mark of group companies. Conduct the quarterly meetings among themselves. Final authority lies with steering committee in case of any disputes related to the 5S scores, 5S audits

etc.

5S STEERING COMMITTEE

5S ZONAL LEADER

5S DEPUTY LEADER

5S FTR/ COORDINATOR

5S CHAMPION

5S TEAM MEMBERS

5S AUDITOR’S COMMITTEE


5S Coordinator/ FTR: Ensures that 5S Reviews are going on as per schedule. Communicates with 5S Champion, Steering Committee, Consultants and everyone involved. Ensures complete implementation of 5S across plant. Organizing the refresher trainings for zonal leaders, Deputy leaders and operators Ensures completion of organisational 5S KPI’s Compilation of all 5S related data. Organisation of 5S audits and coordination for 5S reviews. Reviews the deviation taken by any section Facilitates work group implementation activities. Motivates and monitor implementation activities. Ensures total organisation participation. Acts as a resource for information. Revision of the audit check sheets and standards at shop floor Resolves dispute related to 5S Audits, difference in opinion etc.

Zonal Leaders:

5S Implementation and Sustenance Participation in work group implementation process. Communication with everyone involved within the zone. Motivates work groups. Monitoring progress of group activities. Ensures 5S score achievement/ Improvement Generation of the resource requirement (if any)

Deputy Leaders:

Facilitates all the functions of leader. Assist Zonal leaders in 4S and 5S activities Takes the responsibility in the absence of a leader Conduct 5S Internal Audits and take corrective actions against the abnormalities. Supports in closing the Internal Auditing findings Compilation of the Audit Score and make the graphical trends

Team members’ responsibilities:

Follows the 5S guidelines in letter & sprit including emphasis on 2S. Facilitates and support the activities of a leader Ensures the compliance of specific activities allocated by leader or deputy leader for 5S

implementation Provides support in closing the Internal Auditing findings Contact Deputy Leader for any resource requirement


Setup 5S Zones: Obtain the layout of the entire work area and divide each section into different zones. Assign one team to each section and determine the no. of people per team. Assign a Zonal leader and Deputy leader of the team. Make a Team Charter having names of Zonal leader, Deputy Zonal Leader and team members.

Display the charter with photographs at respective zones. Define roles and responsibilities of the members.

5S Training: Objective: To disseminate 5S methodology and prepare the workforce for meaningful participation in 5S Activities. The training should proceed as follows:

a) 5S Awareness for top management b) 5S Awareness for Operators c) 5S Internal Auditor Program for HOD’s, Zonal Leaders and Deputy Leaders d) 5S Refresher trainings to Operators every quarter.

5S Launch: Announce of 5S Policy, Objectives and Goals Announcement of 5S Organisation and team members Announcement of Award/ Reward Policy

Phase II: PREPARATION OF 1S-2S-3S Preparation of 1S:

1. Red tag identification 2. Removal of Red tag 3. Identify red tag area 4. Provide resources like dustbins etc 5. Procedures like 5W 1H for waste disposal

Preparation of 2S:

1. Identify the place for everything 2. Follow the principles of: a) Easy to Store b) Easy to pick up c) Easy to retrieve d) Less handling 3. Keep the items at location 4. Put Yellow markings, labels, paints etc for them

Preparation of 3S:

1. Clean the area- Dust, oil from the floor 2. Identify the source of dust, oil leakages, pigeon droppings etc. 3. Take Correction and Corrective actions 4. Document 5W 1H for cleaning the area.


4S of 1S (Min- Max Levels)

PHASE III: AUDITING and IMPROVING 1. Prepare audit check sheet 2. Conduct audits 3. Display and share the scores 4. Take corrective and correction actions (DTR)

PHASE IV: SUSTAINING 5S IMPACT CYCLE

1. Prepare 5S audit plan on LPA principle 2. Conduct 5S auditor/ trainer trainings 3. Conduct audit as per LPA 4. Prepare recognition/ reward system 5. Conduct refresher trainings 6. Prepare 5S procedure and integrate in current QMS/ ISO systems 7. Observe the trends for 5-6 audits minimum

4S (Standards) of 1S, 2S and 3S: Purpose/Objectives: To make the participants aware about the importance of 4S of 1S, 4S of 2S and 4S of 3S. Refer to the photographs below showing all the three standards separately.


4S of 2S

5S Typical Road Map for any Organization:

Step 1: Make 5S Policy, Objectives, Goals, Award/ Reward policy etc.

Step 2: Form 5S Council and define roles and responsibility of council members.

Step 3: Set up 5S Zones and Assign Zonal Leaders (Take few pilot areas initially)

Step 4: Conduct refresher training of 5S to top management, middle management and workers.

Step 5: Preparation of 1S, 2S and 3S

Step 6: Preparation of 4S (Standards for 1S, 2S and 3S)

Step 7: Conduct 5S Internal Auditor training program and create Internal Auditors to conduct 5S

Audits.

Step 8: Prepare 5S Audit Check sheets

Step 9: Prepare Layered Process Audit document (LPA)

Step 10: Conduct Audits according to LPA

Step 11: Display the 5S Audit trends

Step 12: Take Corrective and Correction Actions for lower scores

Step 13: Conduct Refresher training on 5S

Step 14: Motivate the team by Award/ Rewards.

Step 15: Prepare 5S Procedure and integrate in current QMS/ ISO systems

Refer to the Video in Chapter- 5 explaining the typical road map of any Organization

4S of 3S (Cleaning Schedule)

4S of 2S (Labelling/ Markings)


Exercise 5.1- Importance of 4th S in 5S Purpose/Objectives: To make the participants aware about the importance of 4th S/ Visuals

Instruction Delegation: Assume that all milestones on the highways in the world are removed. Imagine and write down difficulties you face in this situation.

Duration: 10 min

Reflection: Can you imagine how much fuel is wasted? How many people getting down from vehicles and enquire for the destination address.

chapter 5: phase wise road map of 5s - lean online … 5- phases, road map.pdf · chapter 5: phase...

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