total quality management - spring 2010 - iug1 total quality management week # 11 5s prepared by:...
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Total Quality Management - Spring 2010 - IUG 1
Total Quality ManagementTotal Quality Management
Week # 11Week # 11
5S5S
Prepared by: Khalid DahleezPrepared by: Khalid Dahleez
Faculty of Commerce – the Islamic Faculty of Commerce – the Islamic University of GazaUniversity of Gaza
This material was collected from different sourcesThis material was collected from different sources
Total Quality Management - Spring 2010 - IUG 2
WHAT IS 5S? IN ORDER TO ACHIEVE HIGH LEVELS OF
QUALITY, SAFETY,AND PRODUCTIVITY, WORKERS MUST HAVE A CONDUCIVE WORKING ENVIRONMENT
Developed by the Japanese Housekeeping System Helps Create a Better Working Environment
and a Consistently High Quality Process
Total Quality Management - Spring 2010 - IUG 3
What is 5S? An easy definition is: Finding a place for
everything and putting everything in its place. 5S is also the foundation for Continual Improvement
(CI) and Lean implementation.
It’s a mindset & commitment to achieve a totally waste-free operation that’s focused on your customer’s success… achieved by simplifying and continuously improving all processes
It’s the elimination of waste Everywhere – while adding customer value…
Total Quality Management - Spring 2010 - IUG 4
1. Sei-ri (Organization)2. Sei-ton (Neatness)3. Sei-so (Cleaning)4. Sei-ke-tsu (Standardization)5. Shi-tsu-ke (Self-discipline)
5S ONCSS
5S stands for 5 initials of the following Japanese words:
3
Total Quality Management - Spring 2010 - IUG 5
THE 5S PRINCIPLES
SEIRI – Organisation/Sort out
SEITON – Orderliness/Systemize
SEISO – The Cleaning/Shining
SEIKETSU – STANDARDIZE
SHITSUKE - Sustain/Discipline
Total Quality Management - Spring 2010 - IUG 6
DISCOVERY OF 5S
Thirty years ago researchers started studying the secret of success of Japanese manufacturing companies
5S turned out to be the most impressive "secret"
The factories were so well organized that abnormal situations were readily apparent
Equipments were so clean and well maintained that any problem such as a loose bolt or leaking oil could be easily seen
This passion of cleanliness and orderliness became a hallmark of Japanese organizations
Total Quality Management - Spring 2010 - IUG 7
• Dictionary definition: To put things in order (or organize them) according to a specific rule or principle.
• Industrial definition: To distinguish between necessary things and unnecessary things, and getting rid of what you do not need.
Seiri = Organization (SORT)
means we remove all items from the workplace that are not needed for current production (parts, tools, equipment, etc).
Total Quality Management - Spring 2010 - IUG 8
1. ORGANISATION(SEIRI)
Decide what you need Remove unnecessary clutter All tools, gauges, materials, classified and
then stored Remove items which are broken, unusable
or only occasionally used Key Words:
1. Classification management (Necessary & unnecessary things)
2. Red tag movement3. For unnecessary things, find their true
causes.
Total Quality Management - Spring 2010 - IUG 9
Why is my desk gettingWhy is my desk getting messy? messy?
Necessary UnnecessaryNot necessary
now, but maybe in the future
Every item on my desk belongs to the gray circle
Total Quality Management - Spring 2010 - IUG 10
Do you throw these things away?
It works!
It has a value!
It’s still new!
It’s usable!
It looks nice!
Not necessary now, but maybe
in the future
Total Quality Management - Spring 2010 - IUG 11
RED TAG TECHNIQUE
GIVE STAFF RED LABELS ASK STAFF TO GO THROUGH EVERY
ITEM IN THE WORK PLACE ASK IF NEEDED & THOSE THAT ARE
NEEDED,IN WHAT QUANTITY NOT NEEDED (RED TAG IT ) STORE IN THE RED TAG AREA
RED TAG
Total Quality Management - Spring 2010 - IUG 12
For wavering items
PLACE THE SUSPECTED ITEMS IN THE RED TAG AREA FOR ONE WEEK
ALLOW THE STAFF TO REEVALUATE THE NEEDED ITEMS
AT THE END OF WEEK THOSE WHO NEED ITEMS SHOULD BE RETURNED
REDTAG
Total Quality Management - Spring 2010 - IUG 13
1. Eliminate defects and breakage
2. Organize the warehouse
Before AfterT. Sugiyama “The 5S Approach to Improvement” PHP, 1995
Typical Seiri Activities
Total Quality Management - Spring 2010 - IUG 14
Dictionary definition: Establishing a neat layout so that you can always get just as much of what you need when you need it.
Industrial definition: It is a way of eliminating search.
Seiton = Neatness - Orderliness - Set in Order
ONCE YOU HAVE ELIMINATED ALL THE UNNEEDED ITEMS
NOW TURN TO THE LEFT OVER ITEMS
Total Quality Management - Spring 2010 - IUG 15
How long is your patience?5 minutes? 2 minutes??
or5 seconds???
Question When you ask someone to bring a hammer, how long can you wait without getting mad?
Organise layout of tools and equipment:1.Designated locations2.Use tapes and labels 3.Ensure everything is available as it is needed and
at the “point of use”
Total Quality Management - Spring 2010 - IUG 16
30 Second Rule
Workplace Checkpoints:-1. Positions of aisles and
storage places clearly marked?
2. Tools classified and stored by frequency of use?
3. Pallets stacked correctly?4. Safety equipment easily
accessible?5. Floors in good condition?
Total Quality Management - Spring 2010 - IUG 17
Key Words:Design an efficient layout (Functional storage)Eliminate search (Less search)Everything should have a name.(A place for everything and everything in its place)
Typical Seiton Activities:Stripes on filesFirst in, first outEasy to read notices
Key Words & Typical Activities
Total Quality Management - Spring 2010 - IUG 18
3. SEISO (CLEAN/SHINE) Create a spotless workplace Identify and eliminate causes of dirt and grime –
remove the need to clean Sweep, dust, polish and paint
Definition: Eliminating trash, filth, and foreign matters for a cleaner workplace. Cleaning as a form of inspection.
• SHINE means we sweep floors, scrub machines, apply a fresh coat of paint, and then we KEEP it that way. This way, everything will be in top working condition so that it may be used when it is needed.
• It also means preventive maintenance.
Total Quality Management - Spring 2010 - IUG 19
Keep things clean + Inspection (Caring attitude)
Key Words:
1. Divide areas into zones2. Define responsibilities for cleaning3. Tools and equipment must be owned by
an individual4. Focus on removing the need to clean
Total Quality Management - Spring 2010 - IUG 20
Sanitation engineers
Laundry
Dry cleaner
Janitor
Garbage collector
Pollution control operator
Clean-room designer
One-third (1/3) or one-fourth (1/4) of the total investment amount is used for cleanliness.
Cleanliness is a big business today.
Total Quality Management - Spring 2010 - IUG 21
4. SEIKETSU (STANDARDISE)
Generate a maintenance system for the first three
Develop procedures, schedules, practices Continue to assess the use and disposal of
items Regularly audit using checklists and
measures of housekeeping Real challenge is to keep it clean
Total Quality Management - Spring 2010 - IUG 22
Definition:Keeping things organized, neat, and clean, even in personal and environment aspects.
Seiketsu = Standardization
SEIRI SEITON
SEISO
Total Quality Management - Spring 2010 - IUG 23
Ideal State Current State
GAP
Seiketsu = Standardization
1.Define an ideal state2.Standardize the solution (5S standardization)
Total Quality Management - Spring 2010 - IUG 24
1. Make quality manual2. Directional markings3. Color-coded pipes
Typical Seiketsu Activities
• STANDARDIZATION happens when the first three S’s are properly implemented and maintained.
• It means that racking, paint colors, labeling, operational layouts are designed in a standard fashion.
• Everything will be in place so everyone will know exactly what they are responsible for; and, exactly when, where, and, how to do it.
Total Quality Management - Spring 2010 - IUG 25
5. SHITSUKE (SUSTAIN / DISCIPLINE)
Means inoculate courtesy & good habits Driving force behind all 5S Deming’s point number 1: Constancy of
purpose Make it a way of life Part of health and safety Involve the whole workforce* Develop and keep good habits
Total Quality Management - Spring 2010 - IUG 26
Definition:Doing the right things as a matter of course.
Shitsuke = Self-discipline
We SORT areas. We SET IN ORDER work places. We SHINE areas. With STANDARDIZATION it is easy to identify anything out of place.
SUSTAIN is different: It isn’t a single separate activity; We SUSTAIN when we have developed habits of always using the first 4 S’s together on a daily basis.
Total Quality Management - Spring 2010 - IUG 27
1. Habit formation (Make it a habit)2. Create a disciplined workplace
Key Words & Typical Activities
1. Wear your safety shoes2. Exercise time3. No smoking at workplace
Typical Shitsuke Activities
Total Quality Management - Spring 2010 - IUG 28
WHAT U HAVE COME ACROSS
Followings can be harnessed form the 5S1. NEAT & CLEAN WORKPLACE2. SMOOTH WORKING3. NO OBSTRUCTION4. SAFETY INCREASES5. PRODUCTIVITY IMPROVES6. QUALITY IMPROVES7. WASTAGE DECREASE8. MACHINE MAINTENANCE9. VISUAL CONTROL SYSTEM10. EMPLOYEES MOTIVATED11. WORKSTATIONS BECOME SPACIOUS
Total Quality Management - Spring 2010 - IUG 29
SortClear out rarely usedItems by Red Tagging
StraightenOrganize and Label aPlace for Everything
ShineClean ItStandardise
Create Rules to Sustainthe first 3 5’S
SustainUse Regular ManagementAudits to Stay Disciplined Eliminate
Waste
5 S’s
Total Quality Management - Spring 2010 - IUG 30
When Does 5S Happen?
ALL THE TIME!! 5S is a mindset and a culture. The 5S’s are a part of each Associate’s workday. There will also be CI Events and WPO (WorkPlace Organization) Events. In an Event, Associates are taught how to implement the principles of Continual Improvement.
Total Quality Management - Spring 2010 - IUG 31
How is 5S Implemented? By the associates! Who has a better idea
to make our jobs easier than us? Our management is committed to improving how we work.
We want to work smarter, not harder. Along the way, support will come from EVERYONE.
We will teach the 5S process, and together we will implement it and make it work.
Total Quality Management - Spring 2010 - IUG 32
ADVANTAGES OF 5S If tools and materials are conveniently located in
uncluttered work areas
Operators spend less time looking for items This leads to higher workstation efficiency, a
fundamental goal in mass production
A clean and tidy workplace leads to greater well being
and increased motivation
Company image improves
Total Quality Management - Spring 2010 - IUG 33
ADVANTAGES OF 5S Health and Safety is ensured Machine maintenance Quality Productivity Lean Manufacturing TIME SAVING QUICK RETRIEVAL ACCIDENTS & MISTAKES MINIMIZED INCREASES SPACE CREATES WORKPLACE OWNERSHIP
Total Quality Management - Spring 2010 - IUG 34
ADVANTAGES OF 5S RESULTS IN A PLACE EASIER TO MANAGE SMOOTH WORKING NO OBSTRUCTION NO DEVIATION, NO PROBLEMS
B/C EVERYONE KNOWS WHERE THE THINGS ARE SPPOSEDF TO BE
Total Quality Management - Spring 2010 - IUG 35
ADVANTAGES OF 5S FOUNDATION OF ALL QC TOOLS
CONTINUOUS QUALITY IMPROVEMENT LEAN MANUFACTURING KINDERGARTEN OF QUALITY TOOLS &
TECHNIQUES
Total Quality Management - Spring 2010 - IUG 36
ADVANTAGES OF 5S VISUAL MANAGEMENT SYSTEM
VISUAL CONTROL TO SEE THE ABNORMALITIES
SIMPLE SIGNALS THAT PROVIDE AN UNDERSTANDING OF THE CONDITION( NORMAL/ ABNORMAL)
A LOOK AT THE PROCESS REVEALS ITS DIRECTION (RIGHT/WRONG)