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Path Towards Achieving Excellence

Linking Strategic
QCDIP with Alignment- Big
Unit Goals Ys of Business
Result- Accelerating
Process Six Sigma
linkages
Project
Formation of Losses Orientation
CFTs Waste
Cycle time / QCO
Abnormality Internal
Management Customer
5S QCDIP
Safety, Health &
Environment
Autonomous
Maintenance
 Mission, Values & Str
n, ate
s io gy
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ulture & Passion

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t,

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Market &
nds

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Customer

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Orientation

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M

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Share
holders Value
 TQM TPM
Internal Customer Self Maintenance
Safety
Work Environment

WCM

Six Sigma Lean

Voice of Customer Value Stream
Process Map Muda Elimination
What is WCM

It is a approach to improve the business

through a combination of proven modern
management tools and techniques.
How it Works?
Three Basic Steps

Form the Team

Equip the Teams
Create Competition
Form the Team

Divide the business into small cross
functional, multi-
multi- skilled Teams

Assign Area of Ownership to teams

Functional Orientation to Process
orientation
Equip the Teams
With

Values & Mindset

Concepts, Tools & Techniques

Evolved from WCM Model

 What Mindset?

Mindset that

Rejects abnormalities

Respects the Standards

Teams need to develop eye for

abnormalities / equipment and process
deviations
What is WCM Model?
ission, Values & Stra

Model for achieving isio
n, M teg
y
V
Competitive advantage

Te
a
Incorporates best of the

ms

- In
sp i r
proven methods/ tools/

ture & Passion

a tio n ,
techniques

C reativ ity

Brings clear focus on

, C ul
eight major areas to be

& Co
dset
Market &

looked into by Customer

nt
n

inu
Mi
Orientation

ou
individuals, teams, Units

Le s
ar
n
and Businesses
ing
Share
holders Value
 i ssion, Values & St
o n,M rate
gy
isi
V

Te
a
ms
- In
spir
tu r e & P a s s i o n

at
ion , Creeativity & Co
e t , C ul

Market &
ds

Customer

nt
n

i
Mi

Orientation

nu
u o
s L e
ar
ing n

Share
holders Value
Dimension 1

WORK
ENVIRONMENT
We need to create an ideal
Work Environment in terms of:

Basic Upkeep

Safety
Dimension 1: Work Environment Tells about Basic Upkeep

Basic Upkeep

Basic upkeep means keeping things in a manner

that they has to be
For Basic Upkeep 5S is the Best Tool
 Why 5S ?
(1) Customer wants it !

(2) Helps develop proactive attitude

among the participants

(3) Helps create Safer, Cleaner workplace

(4) Helps eliminate waste..

Waste related to

 Unsafe Conditions

 Inventory

 Space

 Reworks
Paint brush 1 Spanner 1 Screw driver Measure tape

Paint brush 2 Spanner 2 Hammer Cutting wheel

Drill M/C 1 Plumber spanner Plyar Saw

Drill M/C 2 Horticulter tool Vice Torch

Paint brush 1 Spanner 1 Screw driver Measure tape

Paint brush 2 Spanner 2 Hammer Cutting wheel

Drill M/C 1 Plumber spanner Plyar Saw

Drill M/C 2 Horticulter tool Vice Torch

 Work Environment - (5S)

1S - SEIRI - SEGREGATION
2S - SEITON - SYSTEMATIC
ARRANGEMENT
3S - SEISO - SPICK & SPAN
4S - SEIKETSU - STANDARDISING
5S - SHITSUKE - SELF DISCIPLINE

A SOURCE OF PRIDE
Work Environment - (5S)

Products / Customer
Services Satisfaction
Work Environment - (5S)

S
S H
E I
S I T
E K S
E
I U
T
SEITON S S K
SEIRI O U E
 Work Environment - (5S)

5S stands for five good housekeeping

What are 5S ? principles.
5S becomes a base for continuous
improvement.
5S principles are very effective
systematic approach for improving our
work environment and total quality.
5S are participation programme.
5S is based on the belief that every
individual can contribute to improve
his/her workplace where he / she spends
one third of his / her life.
 1S - SEIRI SEGREGATION (SORTING)
SEIRI means to distinguish between what is necessary and what is
unnecessary in accordance with specific rules and principles and
get rid of what you do not need.

Saving things and information

which
one does not need consume
extra space and
create more wok.

SEIRI is excellent way to gain valuable floor space

and eliminate scrap and excess raw material.
 1S - SEIRI - SEGREGATION
What is the criteria to distinguish necessary and unnecessary ?

Unnecessary things with no value Throw away / get rid of

Unnecessary things with value Put in safe custody
Things still used and needed Place in the right location
and identify with tag
Sort them out
Acceptable spares mixed with
reject

Customer does not pay for waste.

 1S - SEIRI - SEGREGATION
How to implement SEIRI - 1S ?

 Clarify standards to judge the necessary things from

the unnecessary.
 Segregate the things in compliance with the set
standard.
 Extended decision making is prohibited.
 Schedule the itinerary checking by promotion
committee members.
 Eliminate the space to store unnecessary things in
order to expel such things.
 Do not hurry to expand the space.
 1S - SEIRI - SEGREGATION
Where unnecessary things can be found ?

 Shelves & Lockers - surplus/broken articles

 Passageway and corners- useless articles
 Behind pillars and under stairs- materials, defective
 Warehouses and sheds- materials/in process articles
Walls and notice boards- expired notice

Behind and also under the machines-broken articles

 Under the floor and side ditches- scrap
 Materials and in process articles
Outskirts ( Near the wall, fences, and drainage)
 Flow Diagram For 1S
Take Photos/Video
of the present location Seiri Start

Scrap Out Of order Ok for Use

Can be Repaired Can not be repaired Required Not Required

To be Repaired To be Scraped Can Be repaired Can not be repaired

Get Repaired Disposal Scrap Cant be Used Can be Use Develop System
for Disposal

Disposal Scrap Shift to proper place Arrange Disposal

Useful Material Disposal

End Of Seiri
Zone the office Area: photograph the worst areas

Allocate cleaning and inspection responsibilities

Clear obviously unnecessary items not used in the last 12

months

Agree disposal criteria for on going control

Tag / label items which need review / for use elsewhere,

including dealing with defective parts (are they useful?)

Relocate items based on usage level

Clean every inch including inaccessible nooks and corners

Develop an initial standard (photographs)
Communicate
Identify all abnormalities, sources of contamination and
hard to clean places
 Seiri : Sort out items and discard
the unnecessary
Check :
1.Do you find items scattered in your
workplace
2.Are there boxes, papers and other
items left in a disorganized manner.
manner.
3.Are there equipments and tools placed
on the floor
floor..
4.Are all items sorted out and placed in
designated spots.
spots.
5.Are the tools properly sorted and
stored
1S - SEIRI - SEGREGATION
Benefits from SEIRI

Eliminate the excess use of space.

Eliminate the excess equipment.
Eliminates the excess use of file
cabinet / shelf.
Eliminates accidents.
Eliminates errors.
Eliminate waste of time
Reduce cost of production.
Identify The Things and Count
Count Now - How Much It Is Easy just by keeping everything
on its Place
Computers Flags Clocks

Telephones Stars Pens

2S - SEITON - SYSTEMATIC ARRANGEMENT
What to do with segregated necessary things ?

SEITON(SYSTEMATIC-ARRANGEMENT)
means having things in the right place or right
location. It is for the most efficient and effective
retrieval. Make a system which enables anyone to
take out the thing promptly.

A place for everything and

everything on its place
 2S - SEITON - SYSTEMATIC ARRANGEMENT
How to implement SEITON ?

 Fix the storage space.

 Clearly indicate the storage location.
 Unify the names of thing.
 Stratify things.
 Things which are used once or twice a year ---
to be stored in remote place.
 Things which are used about once a month ---
to be placed collectively in the work place.
 Things which are used daily --- to be placed
within the work area.
2S - SEITON - SYSTEMATIC ARRANGEMENT

 Decide how to put things.

 In relation to quality.
 Avoid placing the things which resemble
each other together. Show the difference
clearly.
 Indicate the storage period.
 Use the first in first out method (FIFO).
 Distinguish clearly between good and
inferior quality goods.
2S - SEITON - SYSTEMATIC ARRANGEMENT

 Establish a storage standard.

 Being taken away--- Who did it,
when is the return date?
 Out of stock--- Is there backup
supply?
 Stock replenishment---Who places an
order, to whom and for what quantity.

Way of eliminating the unproductive time

spent in looking for necessary things.
2S - SEITON - SYSTEMATIC ARRANGEMENT

 Decide how to put things.

 In relation to efficiency.
 Assigned place marking, putting things visibly
in place.
 Location --- self numbers
 Layout --- minimization of movement.
 Ease of removal and storing.

 In relation to SAFETY
 Put heavy weights at lower place.
 Prevent overturn and drops.
Arrange necessary items in orderly way

Activities :
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
Success indicators :
1. Time saved in searching
2. Time saved in handling material
 Seiton :Arrange a place for everything.
Everything in its place.
Check :
1. Are passages and storage
places clearly indicated.
2.Are commonly used tools
separated from those
seldom used.
3.Are containers and boxes
stacked up properly.
4.Are fire extinguishers and
hydrants readily accessible.
5.Are there grooves, cracks
or bumps on the floor which
hinder work or safety.
 Flow Diagram For 2S

Start Seiton Take Photos/Video Remove Decide place of

Before Seiton Unnecessary Item storage and rearrange

Use colour codes and

light indicator show arrows Put tag on every thing Decide place for every thing

Doors of work place Provide facilities to Use standard colors for pipes
roads to have direction board minimise tools of water, gas, chemical etc

Decide frequency record Keep record of specific areas Make caution board,
& record & review and colour codes notice board clearly visible

End Seiton
2S - SEITON - SYSTEMATIC ARRANGEMENT
Benefit from SEITON

Helps to reduce time for finding useful

material .
Create work effectiveness.
Create safe atmosphere.
Easy to inspect and recognize when material
are gone from their location.
Draw Out File No. 5
 3S - SEISO - SPICK AND SPAN
Are floors and machines
cleaned for the sake of
appearance????

SEISO(SWEEPING/CLEANING) means
getting rid of waste, grime and foreign matter
and making things clean. Make a system which
eliminates the cause of dirtiness.

CLEANING AS A FORM OF
INSPECTION.
 3S - SEISO - SPICK AND SPAN
WHY to do SEISO ?

SEISO ( Cleaning) is a philosophy and

commitment to be responsible for all aspects of the
things you use and to ensure that they are in tip top
condition
Dust, dirt, grime, foreign matter etc. are looked
upon as the prime causes for unexpected failure of
equipment, unhygienic environment and even
accidents.
Therefore SEISO should be viewed as way to
eliminate these problems one by one.
CLEANING IS A EVERYBODY
BUSINESS.
 3S - SEISO - SPICK AND SPAN
How proper cleaning to be done?

Following steps to be followed for doing proper

cleaning:

 Measures against the root of uncleanliness.

 Investigation of the root of uncleanliness.
 Measures against the cause of uncleanliness
 Prevention of leakage
 prevention of scattering
 prevention of falling
 study of manufacturing method
 Correct looseness
3S - SEISO - SPICK AND SPAN
 How to deal with places which cannot be cleaned easily ?
 Devise effective means to collect and dispose of dust.
 Review of dust collection capacity and method,
cleaning equipment and method of washing.

 Cleaning of workplace
 Allotment of areas and equipment to be cleaned
First allot the area by group, then allot a related job
by person.
 Do Cleaning
 Detect abnormal condition while cleaning.
 Establish cleaning rules.
Decide when to do cleaning.
SEISO - Cleaning

This step eliminates dirt, dust and other foreign

matter to make work place clean and polished.
Activities :
1. Clean equipment, tool, furniture, records
etc..
2. Keep the workplace spotless.
3. Sweeping, wiping, polishing, painting,
etc..
Success indicators :
1. Reduction in machine downtime
2. Increased life of the machine parts
3. Reduction in number of accidents
4. Reduction in rejection / rework
 Cleaning & Inspection Checklist
Deptt.: Corp WCM Area: Conference Hall
S.No. Element Standards Method Tool Time Cycle Responsibility 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 Door No Dust Wipe 1 min. Suresh
No Stains Wipe 1 min. Suresh
No Jamming 30 sec Suresh
2 Floor/ Carpet No Dust Wipe 1 min. Suresh
No Stains Wipe 1 min. Suresh
3 Table No Dust Wipe 1 min. Suresh
No Stains Wipe 1 min. Suresh
Items placed at
proper places as Concerned
per the standards 1 min. person
4 Chairs No Dust Wipe 1 min. Suresh
No Stains Wipe 1 min. Suresh
Placed properly 30 sec Suresh
5 Light Fixtures No Dust Wipe 1 min. Suresh
No Stains Wipe 1 min. Suresh
Working in top Concerned
condition 30 sec person
Concerned
6 Miscellaneous No abnormal smell 30 sec person
Concerned
No abnormal sound 30 sec person
Concerned
No pests 1 min. person
Daily Weekly
Seiso : Clean your workplace thoroughly.

Check :
1. Are the floor surfaces dirty
dirty..
2. Are machines and equipment
dirty..
dirty
3. Are wires and pipes dirty or
stained..
stained
4. Are machine nozzles dirty by
lubricants and inks.
inks.
5. Are shades, light bulbs and
light reflectors dirty
dirty..
 Flow Diagram For 3S
Start Seiso

Take Photos/Video Devide work place

Train all on 5S
Cleaning status in to zone and subzones

Decide order of
Leader to implementation Decide leader of
Sweeping/cleaning &
Seiso by(LLF method) each zone/subzone
make list of facilities

Use Appropriate Make rules & standards

Collect Facilities for cleaning & ensure implementation
Tools for cleaning

Improve continuously by Review weekly/monthly

Create Interest
Practicing kaizens & identify causes
and enthusiasm
Of systems lapses

End Seiton
3S - SEISO - SPICK AND SPAN
 Cleaning of equipment
 Do cleaning by a check sheet.
 Wipe out dirt.
 Cleaning of clogged filters, pipes etc.
 Control of generation of heat and other temp.
 Correction of displacement.
 Teaching of equipment and facilities element
 General equipment and facilities check point
 Check point for cleaning.
 Check points for oil
 Check points for additional tightening
 check point for temperature control
check point for breakage.
4S - SEIKETSU - STANDARDIZE
What do you mean by
SEIKETSU

Seiketsu(Standardize) means continually and

repeatedly maintain 1S, 2S & 3S standard
achieved. Make a system which enables quick
detection of a disordered condition / state.

It must be made possible for

anyone to see the actual
situation at a glance by means of
the visual control
 4S - SEIKETSU - STANDARDIZE
How to maintain 1S, 2S & 3S ?

Standardization is a condition where the segregation,

Systematic arrangement and Cleaning have been
repeated and maintained. Introduce extensive visual
controls so that abnormalities show up by
themselves.
Following steps to be followed to maintain and
promulgate first three S more deeply.
 Points of visual control
 Standards for what is good and bad are clear.
 Abnormal conditions are shown.
4S - SEIKETSU - STANDARDIZE
 Tools of visual control
 Label - lubrication label, accuracy label,
inspection label, equipment number and
category.
 Limit marking - meter zone, stop line,
assigned place marking, danger alert.
 Visualization - Status indication, direction
indication, maintenance display board,
Instructions, colour code for pipes, picture of
safety gadgets to be used in the area, direction
sign for emergency points & fire extinguisher,
Caution and operation reminders.
 Seiketsu :Maintain a standard.

Check :
1. Is any ones uniform dirty and untidy
2. Are there sufficient lights
lights..
3. Is the noise or heat at your workplace
causing discomfort.
discomfort.
4. Is the roof leaking
5. Do people eat at designated places only
only..
 4S - SEIKETSU - STANDARDIZE

 PREVENTS THE 1S, 2S AND 3S

RETURNING TO 0S !!!!!
 PROPER AND NICE WORKING AREAS.
 STANDARD OPERATIONS AND
PROCEDURES.
 CREATE EXCELLENT PHYSICAL AND
MENTAL HEALTHS.
IT MEANS HAVING THE ABILITY TO DO
THINGS THE WAY THEY ARE
SUPPOSED TO BE DONE. THE
EMPHASIS IS ON CREATING A
WORKPLACE WITH GOOD
HABITS AND DISCIPLINE.

Doing the right things as routine.

5S - SHITSUKE - SELF
SELF-- DISCIPLINE

Discipline means to get accustomed to the

operation in compliance with standards. It is the
discipline to honor faithfully the promises agreed
upon by the fellow people.
The purpose of SHITSUKE is to support the
four S ( Segregation, Systematic arrangement,
Spick & Span and Standardizing) as the means to
satisfy such fundamental things.

Keep practicing the activities

through those procedure
until they become habits.
 5S - SHITSUKE - SELF
SELF-- DISCIPLINE

Discipline means thinking about the many

problems that occur day to day and resolving
to do better.
People sometimes make the most
unbelievable mistakes because they let their
guard down- because they forget their
discipline.Practice and more practice.
When you assume that something
is easy just because you have
done it thousand of times, that is
when you are most likely
to get it wrong.
 Shitsuke :Train people to be disciplined

Check :
1. Are regular 5 - S checks
conducted.
2. Do people clean up without
reminders.
3. Do people follow rules and
instructions.
4. Do people wear their uniforms
and safety gears properly.
5. Do people assemble on time.
 5 Levels of Housekeeping
Level - 1 Horizontal surface - floor full of unwanted
materials

Level-- 2 Vertical surfaces - areas near walls having

Level
clutter

Level-- 3 Horizontal - vertical surfaces clean and `

Level
have no unwanted items, however storage
areas, record rooms disorganised

Level - 4 Storage areas, m/cs, offices are clean.

clean. All
materials, furnitures, documents properly
organised, labelled and numbered

Level - 5 Factory/offices are immaculate at all the

times
Housekeeping
H ousekeeping is everybodys responsibility
O bservation of abnormalities
U nwanted things are removed
S cope for space generation
E agerness to look neat & clean
K aleiodoscopic view
E liminates waste
E asy accessibility
P revents accidents
I mproves workplace
N ew ideas are generated
G angways are cleared