for house keeping

7/31/2019 For House Keeping

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Is a participative programme.

It is a very effective approach to improvingour work,environment and total quality.

It becomes a base for continuousimprovement in the organisation

5S---


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Summary

5s is a systematic approach to goodhousekeeping.

It is today gaining strong support in mostindustries, especially in Japan and thereare increasing number of companies

which are implementing 5s with greaterinvolvement of people within theorganisation.


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Why is it becoming popular amongcompanies in Japan? Simply because:

1. Workplace becomes clean and better organised2. Shopfloor and office operations become easier and

safer

3. Results are visible to everyone insiders and outsiders

4. Visible results enhance generation of more newideas

5. People are automatically disciplined

6. People become proud of a clean and organisedworkplace

7. Resultant good company image generates morebusiness etc.


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Some significant benefits observedat companies practising 5s include:

1. Happier employees with high morale.2. Greater people involvement.

3. Low employee turnover.

4. Increased number of suggestions.

5. Better use of floor space.

6. Less work-in-progress and inventories.

7. Better flow of work.

8. Low machine breakdown rates.9. Low accident rates.

10. High yield of materials.

11. High product quality.


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The assumption why 5S is becoming sopopular in Japan in recent years and in othercountries today is that it emphasizes a people-oriented and also practice-oriented approach.

5S expects everyone-indeed everyone-toparticipate in it.

It is based on the belief that every individualcan contribute to improving his/her workplacewhere he/she spends one-third of his/her life.


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What is 5S?

The concept of good housekeeping has been with theJapanese for a very long time.At home and in school,children are disciplined to adhere to good housekeepingpractices.However, it was only in the early 1980s thatgood houskepping became a pertinent issue in Japaneseindustries as companies realised its powerful contributionto productivity and quality improvement.

The basis for good housekeeping in Japanesecompanies is a concept popularly known as 5S.Thisstands for the five good housekeeping concepts inJapanese.


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y a - movemen 1. Human beings feel good if work place is clean and well

organised.

2. Helps in reducing timea. For searching things

b. For handling

3. Helps in reducing

a. Waste, inconsistencies & strainb. Unnecessary items & reserve stock

c. Space requirement

d. Machine downtime

e. Rejection / Rework

f. Number of accidents

Helps people

a. In seeing things more clearly

b. In changing mindsets-develop a proactive attitude


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Meaning of 5S

1. Segregation (SEIRI)

2. Arrangement (SEITON)

3. Cleaning (SEISO)

4. Maintenance of standards (SEIKETSU)

5. Discipline (SHITSUKE)

Wh t i 5S??


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What is 5S??5S Original Japanese Meaning in English

1S SEIRI Sort out unnecessary items in the workplaceand discard them

2S SEITON Arrange necessary items in good order sothat they can be easily picked for use

A place for everythingEverything in its place

3S SEISO Clean your workplace thoroughly so thatthere is no dust on floors,machines andequipments

4S SEIKETSU Maintain high standards of workplace at alltimes

5S SHITSUKE Train people to follow good housekeepingdiscipline automatically


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Segregation ---SEIRIIt helps to segregate necessary and unnecessary items

and eliminate unnecessary items. It essentially meansorganising / putting things in order.

ACTIVITIES

1.Go through what you have2. Segregate/identify what you need

3. Categorise needed/not needed items

4. Discard What Is Unnecessary

INDICATOR OF SUCCESS

1. Decrease in unnecessary items and reserve stock

2. Percentage of area / space saved


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Arrangement --- SEITON

This step essentially means arranging items efficiently,for

easy accessibility and using them in best orderACTIVITIES

1. Set things in order by creating a place for everything.

2. Put everything in its place

3. Keep accessibility as easy as possible.4. Use the principle of wide range and shallow depth for

storage.


1. Time saved in searching

2. Time saved in handling material


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How to promote good order

Putting in order

Things needed Things not needed

Things usedConstantly

Things used

occasionally

Seldom usedBut still needed

Place as closeas possible

Place a little

further

Enclose in a sepearateDesignated

Place

Potentiallyusefull

No potentialuse

Consider whereusefull and move

to designated place

Disposal aftercareful analysis


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Cleaning ---SEISO

This step eliminates dirt, dust and other foreignmatter to make workplace clean and polished.

ACTIVITIES

1. Clean equipment, tools, furniture, records,etc.

2. Keep the workplace spotless

3. Sweeping, wiping, polishing, painting,etc.


1. Reduction in machine downtime

2. Increased life of the machine parts

3. Reduction in number of accidents

4. Reduction in rejection / rework


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Maintenance to standards ---SEIKETSU

This Step is Combination of segregation (seiri),

arrangement (seiton) and cleaning (seiso). As as,anon-going programme to maintain a clean and wellorganised workplace.

Activities

1. Create standards and initiate steps to maintain them2. Devise ways to

a. Expose hidden problems

b. Surface abnormalities

3. Create visual control systems

Indicator of success

1. Number of areas / covers made transparent

2.

Number of new problems exposed and solved


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What is an Abnormality ?An abnormality is any gap between actual performance

and the appropriate standard

EXAMPLES

Defective goods

Scrap

Equipment Failure

Over Production Lateness

Waiting

Wh i h i l l ?


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What is the visual control ?A visual control communicates required importantinformation to people who need it.

It grabs one or more of our senses in order to :

Alert us to an abnormality

Help us monitor quickly

Promote adherance and prevention Enable successful self management

Visual controls Reduce errors / waste by making problems visible Identify gap between standard and actual performance

Help in early identification of problems

Reduce supervision


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Visual control systemA visual control system (VCS) is a series of visual

and other sensory devices integrated in order toachieve a particular outcome,ensure conformanceand prevent waste

Example

1. Illustration of correct manual operation

2. Part containers colour coded to match the parts

3. Red colour light above the line that goes on whenhelp is needed


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Important Points for preparation ofvisual controls

1. Easy to see from distance

2. Easy to understand

3. Ensure correct location/ placement

4. Use colours for brightness/contrast


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Important areas of visual displays

1. Instructions to people to avoid OPERATION ERRORS

2. Danger alerts/cautions

3. Direction/locations

4. Equipment Designations

5. Planned programmes

6. Preventive maintenance/Calibration displays

7. Appeals


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The Elements of 5S

ORGANISING/PUTTING

things in order sorting1.Removing what is not needed

2.Keeping what is needed

CLEANING

Keeping things clean andpolished,No trash or dirt

anywhere in the workplace

ARRANGEMENT

Placing things so that peoplecan easily reach what they

need whwnever they need it

MAINT.OF STANDARDS

Mainting cleanliness afterorganisation ,arrangement

and cleaning and establishing

DISCIPLINEAdherance to standards developed

through 4S steps by all employees of the

workplace

5 L l f h k i


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5 Levels of housekeeping

LEVELS

1. Horizontal surfaces/floor full of unwanted material.

2. Vertical surfaces / areas near walls having clutter.

3. Horizontal ,vertical surfaces clean and have no unwanteditems.However,storage areas, record rooms disorganised.

4. Storage areas ,machines,offices are clean.All materials,furtinuture,documents properly organised,labelled andnumbered.

5. Factory/office is immaculate at all times.

Level 1 of Housekeeping


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Level 1 of HousekeepingWork area is in level 1 of housekeeping if,

Cigarette butts/Gutkha pouches Scraps of paper

Tools (Used or Unused)

Packing and clamping materials

Support structures

Left -over raw material

Obsolete documents

Bulky files

Unused equipment,machine etc

are scattered around all over the workplace.

Corrective action for level 1


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Look at all horizontal surfaces

Examine the entire work floor.Eliminate all garbage andnon- essential items on floor,shelves,tabletops etc

Remove unnecessary papers from files

Discard old files,stationery etc

Make a definite place for all tools/documents,files and partsthat are lying on the floor tabletops

HINTS FOR IMPROVEMENT

Do not put anything directly on the floor

As much as possible, throw/dispose off things that have noclear foreseeable use.

Le el 2 of ho sekeeping


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Level 2 of housekeepingWork area is in level 2 of housekeeping if there is no litter orunused material on the floor/horizontal surface, but

Clutter is found by the walls

The passage ways are not clear

Unused items,documents,furniture etc are leaning againstthe walls or columns

Unused tools and equipment ,paper left beneath or besidethe equipment



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Look at vertical surfaces

Examine walls and columns

Eliminate all garbage and non- essential items leaning

against the walls/columns

Paint all walls and columns that can be reached by hand

Hint for improvement

Divide responsibilities (For area and walls)

Level 3 of housekeeping


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Work area is in level 3 of housekeeping if the walkways are

clear and the factory/office is clean,but thetools,materials,papers and files are still disorganised in thestorage areas,record rooms,drawers,filing racks etc.

Tools ,parts,clamps are all mixed together

Gloves,shoes etc are thrown in with tools in the toolbox

Drawers,shelves are disorganised

All tools are in locked storage units

Drawers,shelves are locked and keys are missing

Unused and worthless items found inside closed cabinets



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Look inside the shelves and sort the papers, material

,parts and tools

Get rid of locked cabinets

Make separate storages for tools,parts,clamps, documentsetc.

Make the above area distinct and clear

HINT FOR IMPROVEMENT

Remove the back and sides of all the storage cabinets



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At level 4,the work area will have,

Machines,equipment,furnitures spotlessly clean

Storage areas clearly marked and distinguished

Scrap material found in its designated scrap bin

Items placed in shelves are properly labelled/ tagged

Storage areas show many parallel lines and right angles forgrid alignment

Tools/files are colour coded and numbered

Further improvement at Level 4


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Further improvement at Level 4

Clean ,straighten and organise automatically

Storage system designed for First In First Outphilosophy

Develop other visual controls

Hints for improvement

Scrap and chips should fall directly into wastecontainers/dust bins

Make a model line with super market type displayof parts and tools

Well defined scrap & waste collection & disposalsystem


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Level 5 of Housekeeping

At level 5,the work place is immaculate at all times.Itwitnesses,

Constant and continual cleaning by all employees

Origins of rubbish are removed so that dirt,clutter andgarbage are eliminated at source

Tools,items and materials can be found at a glance

Inventory levels can be found visually

Production runs smoothly

High product quality achieved


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Workplace rating

In third rate workplace ,people leave trash andno one stops to pick it up

In second rate workplace, people leave trash butothers pick it up

In first rate workplace, no one leaves trash,but

people would pick it up, if they saw it.

Wh t d 5(S) i ?


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What does 5(S) require?

Consciousness revolution through,

1. Perseverance,determination

2. Training

3. Constant efforts

Abilities

1. To see / judge what is important

2. Attention to details

Continuous implementation through

Total participation by all employees

cruc a po n s or success u


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cruc a po n s or success uimplementation of 5S

PARTICIPATION BY ALL PEOPLE

5S programme should be participated by all People in theorganisation.

One day should be set aside for the launching of theprogramme.

6 objectives or whys of 5S programme should beunderstood by all people in the organisation,

1. A clean workplace is high in PRODUCTIVITY

2. A clean workplace has high QUALITY

3. A clean workplace keeps COST down

4. A clean workplace ensures DELIVERY on time

5. A clean workplace is SAFE for people to work

6. A clean workplace is high in MORALE

The programme would be more effective when it is

included in the small group activities like Quality Circles.


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The CEO should take leadership ofthe programme

The CEO himself should be keen and committedand have a vested interest in the programme.

The CEO should not delegate the leadership toother people.

The CEO should exercise his leadership in 5Ssteering committee.


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The programme should besupported by all

Such doubts Why are the disposal notices posted for SEIRI

? Why is 5S improvement for shopfloor improvement?

should be eliminated.

Each committee member should keep everyone informed ofthe current progress of 5S implementation on adepartmental level.

Each committee member should encourage and guide hispeople for involvement in 5S implementation activities.

5S Programme should be self- sustaining


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5S Programme should be self- sustaining

Banners,slogans,posters and newsletters should be fullyutilized to draw attention of everyone to this programme

An easy handbook or a pamphlet illustrating Why 5SWhat is 5S and How to implement 5S should be printedand distributed to everyone.

Periodic 5S implementation review should be conducted byCEO or an external expert for comments and updating thestatus quo.

Basic in-house training and introduction to modelcompanies that have successfully implemented 5Spractices would not only provide the necessary skills but

also give an insight into how other companies implement5S.

After the company has attained a certain level ofimplementation,participation in Inter- company 5Scompetition should provide greater motivation for further

improvement.


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The CEO should make a periodic factorytour in person

The CEO should tour the factory from time to timeand point out strengths and weaknesses of 5Simplementation in each workplace.

The CEO should advise 5S steering committee totake corrective action in the areas identified.

The CEO should check the progress of theimplementation.

The CEO should give recognition to improved orbetter practice.


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The programme should generatesufficient impact at the initial stage

Slow implementation of decisions by the 5Ssteering committee should be avoided.

Disposal notice approach for SEIRI which is the

first step to 5S should especially be implementedcompany-wide for a specified time before

proceeding to SEITON which is the second step for5S.

Implementation of 5S should go hand in hand with


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Implementation of 5S should go hand in hand withother Kaizen programme

5S especially at SEITON requires certain Kaizen principles and skillswhich can be acquired via external or well organised in-house trainingprogrammes.

SEITON requires logical problem-solving approaches.In this sense,itcan well be a good theme for Quality Circle activities.

SEITON also requires creative ideas from everyone.Therefore,it can betied in with and employee suggestion scheme.

Successful implementation of 5S will,by itself,bring about various

tangible results.It is also a necessary step for a company to go throughbefore implementing advanced management technologies such asTQC,JIT and TPM because 5S buildsup a solid foundation forSHITSUKE.


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F M hi d T l


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From Machines and Tools

Machine troubles can be detected at an earlier

stage to prevent a major breakdown, whenmachines are cleaned daily by people operatingthem.

Daily cleaning of measuring instruments willensure accuracy and reliability.

Life of machines and tools can be extendedsignificantly when they are handled with care andplaced in the designated locations.

From materials and Work in


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From materials and Workin -Progress

Flow of materials and work-in-progress will becomesmoother.

Floor space will become organised and possible areas forimprovement can be easily identified by quick observation.

Inventory of materials and work-in-progress will become

clearly visible and easily handled.

Material yield ratios can be improved


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Housekeeping to Happiness

Housekeeping means Orderliness

Orderliness leads to Cleanliness

Cleanliness leads to Quality

Quality leads to Productivity

Productivity leads to Prosperity

Prosperity means Happiness

for house keeping

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