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Prepared by M.

Ganesh Murugan 9715447621


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Necessity of 5S

Productivity improvement Quality assurance Cost reduction

Job satisfaction
Deadline observation Happy workplace Secure production volume

Workplace improvement

SEIRI SEITON
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SHITSUKE SEISO SEIKETSU


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The 5 Words
Step 1
Seiri Sort

Step 2

Seiton Set in Order

5S is a method that uses five Japanese words which start with the letter S

Step 3

Seiso Shiny clean

Step 4

Seiketsu Standardized cleanup

Step 5
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Shitsuke - Sustain
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5S
5 Steps to a Better Workplace
Safer Boosts Morale More efficient More Reliable

More Profitable

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Why 5 S?
The Purpose of 5S is to promote a safe

and efficient work environment

Not just a cleaning campaign, 5S is a way

to set a new standard that we all agree on and help us get the discipline we need to maintain it.

By Implementing the 5S
Opportunity to improve the own

workplace Team involvement & Problem solving opportunities appears.

5S gives visible and Motivating Results


First step in the implementation of Lean

Manufacturing, TPM an Kaizen.

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Reasons to implement 5S
Improved Safety
No items on the floor Therefore fewer slips or falls Safety device in their right places Less dust

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Reasons to implement 5S
Improved Safety
Fewer break downs
Fewer strange errors from electronic

systems Less wear from dust or grit in moving parts

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Reasons to implement 5S
Improved Safety
Fewer break downs Better work Environment
A clean & well functioning workplace

Fix the unsafe & cluttered work

stations

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Reasons to implement 5S
Improved Safety
Fewer break downs Better work Environment Less Environmental Impact
Leakages such as oil will easily be

spotted Using less floor space may reduce energy consumption

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Reasons to implement 5S
Improved Safety
Fewer break downs Better work Environment Less Environmental Impact Few human errors
Easy to do it right than wrong Safety guards placed properly Less clutter, fewer visual distractions&

easy access to tools and materials

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Reasons to implement 5S
Improved Safety
Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier
When you do 5S , you inspect the

same

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Reasons to implement 5S
Improved Safety
Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier No searching
Effective tools at the right place

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Reasons to implement 5S
Improved Safety
Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier No searching

Higher morale
Through teamwork and visible results

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Reasons to implement 5S

Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier No searching Higher morale Goodwill
Helpfulness to create an

impression.
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The 5 phases in 5S
Step 1
Seiri Sort

Step 2

Seiton Set in Order

Step 3

Seiso Shiny clean

Step 4

Seiketsu Standardized cleanup

Step 5
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Shitsuke - Sustain
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Step 1 - Sorting
Sorting is a team activity that

will be carried out by the production an d maintenance personnel together Sorting has two purposes
Remove unnecessary objects Reduce waste

Step 1

Seiri Sort

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Remove unnecessary Objects


Go through the whole plant
Look for Materials
Behind or under machines Rejects Forgotten materials

Step 1

Seiri Sort

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Remove unnecessary Objects


Go through the whole plant
Look for Materials Tools
Not in use Worn out or broken Custom-made tools (made

Step 1

Seiri Sort

of steel wire/tape/etc-Replace by real tools

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Remove unnecessary Objects


Go through the whole plant
Look for Materials Tools Spare parts
Broken Surplus Inventory Spare parts for machines no

Step 1

Seiri Sort

longer in use

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Remove unnecessary Objects


Go through the whole plant
Look for Materials Tools Spare parts Out-of-date Documentation
Instructions Binders Manuals

Step 1

Seiri Sort

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Remove unnecessary Objects


Go through the whole plant
Look for Materials Tools Spare parts Out-of-date Documentation Bulletin board
Outdated notices Irrelevant information

Step 1

Seiri Sort

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Remove unnecessary Objects


Go through the whole plant
Look for Materials Tools Spare parts Out-of-date Documentation Bulletin board Other stuff
Outdated computer hardware Packing Material Outdated protective equipment
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Step 1

Seiri Sort

Remove unnecessary Objects ?


Look at each object
Ask yourself, Do we need it at all? If not Discard it or sell it Ask yourself, Will we need it soon? If not Put it in proper storage eg:- spare parts, etc. Is it working , but.. Too difficult to use In correct design Too time consuming to use Has a high risk for injury/quality? MGM Not easy to accessible
Step 1

Seiri Sort

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Remove unnecessary Objects ?


Each item to be discarded or

corrected is marked with a red tag

Step 1

Seiri Sort

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Waste elimination
The second purpose of sorting is

to reduce waste and generate ideas for improvements We will try to identify every thing that is hindering us from working safely and efficiently

Step 1

Seiri Sort

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Waste elimination
Try to identify every thing that is

hindering us from working safely and efficiently Work instrutions


Do we have them?
Are they up-to-date? Are they in use? If not why not?

Step 1

Seiri Sort

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Waste elimination
Try to identify every thing that is

hindering us from working safely and efficiently Work instructions Safety


What measures should we take to

Step 1

Seiri Sort

eliminate the risk of fire and accidents?


Remove clutter Improve unsafe electrical

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installations Replace broken safety devices Repair broken components

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Waste elimination
Try to identify every thing that is

hindering us from working safely and efficiently Work instructions Safety Environment
What measures do we need to

Step 1

Seiri Sort

minimize or prevent damage to the environment?

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Waste elimination
Try to identify every thing that is

hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment
Anything missing ?
Anything not working properly ? Anything in need of improvement?

Step 1

Seiri Sort

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Waste elimination
Try to identify every thing that is

hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Inconvenient work positions
Seat & work s/fs at the right height Awkward angles for moving

Step 1

Seiri Sort

materials
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Waste elimination
Try to identify every thing that is

hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Inconvenient work positions Deferred maintenance
Temporary repairs/not properly

Step 1

Seiri Sort

secured MGM Old equipments/technical errors

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Waste elimination
Try to identify every thing that is

hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Inconvenient work positions Deferred maintenance Improvement Proposals
Review prior suggestions

Step 1

Seiri Sort

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Waste elimination
All identified waste items are

marked with an red tag

Machine tagged with errors and improved suggestions


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5S Sort list
Every tag refers to a 5S Sort list
Step 1

Seiri Sort

Think break Do we have any examples of deferred maintenance in our plant?

Tag no

Item description

Session tagged

Date

Tagged by

Responsible

Due date

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Question yourself Seiri


Do you find items scattered at your

place? Are any items left in disorganized way? Are all item sorted and kept in designated place? Are tools and stationeries properly sorted and stored?

Step 1

Seiri Sort

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Step 2 Set in Order


Every tag refers to a 5S Sort list
Seiri Sort

Seiton Set in Order

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Missing letter ?
Every tag refers to a 5S Sort list

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Why-set in order?
The purpose of Seiton set in order

is that everything that we regularly use should have a convenient placement


Tools should be kept at the point of

use No bending to pickup or move materials Alter flow paths to improve efficiency

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Placement
Very rarely used Can be placed outside work room

Item

Long Intervals between the use

Placed near the machine

Frequently used

Placed close to user location

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Efficient layout and color coding


Make a drawing of the current

situation Brainstorm to find an optimal layout Agree the color code Mark the location(removable tapes preferred) of all objects Move the equipments if necessary

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Question yourself Seiton?


Are passages and storages clearly

indicated? Commonly used tools & stationeries separated from the seldom used? Are containers, boxes, materials and fire extinguishers stocked up properly? Are there grooves, cracks or bumps on the floor which hinder work or safely?
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Step 3 Shiny clean


Next step in 5S is to carry out a Shiny clean event
Seiri Sort

Seiton Set in Order

Seiso Shiny clean

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Shiny clean
To keep your area clean on a

continuing basis Clean all machines thorough Clean all equipments, fixtures, and tools Clean the floor, walls, cabinets, shelves etc.

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Why Seiso?
To prevent the area from getting

dirty in the first place, so we dont have to clean it up afterward A clean workplace is indicative of a quality product and process Dust and dirt cause potential health hazards Things to remember : Sweep/Vacuum Dust / Mop
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Guidelines Seiso?
Divide areas into zones Define responsibilities for cleaning Tools and equipment must be owned by an individual Focus on removing the need to clean

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Question yourself Seiso?


Are machines and equipments dirty? Are pipes dirty and corroded? Are nozzles dirtied by lubricants and

ink?
Are shades, lights, bulbs, and light

reflectors dirty?

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Step 4 Standardized cleanup


Continue sorting, storing and cleaning to maintain serene atmosphere at all times
Step 1
Seiri Sort

Step 2

Seiton Set in Order

Step 3

Seiso Shiny clean

Step 4
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Seiketsu Standardized cleanup

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Why Seiketsu?
Prevents regression back to an unclean/disorganized

environment Things to remember : Develop schedules, checklists Periodically evaluate area using 5S Audit sheet Continually improve neatness

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Phases of Seiketsu?
Clarification of vital points for management Things to

remember : What are the minute defects? Basic conditions: Cleanliness, refueling, replace tightly bind fast,

dirt, looseness Operating conditions: pressure, temperature, time, flow volume, weight, Equipment, jigs and tools, sub-materials
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Phases of Seiketsu?
Prepare standards for the conditions Objectification of judgment standards for normal versus abnormal Judgment without using measurement, knowledge, intuition and knack

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Phases of Seiketsu?
Judgment standards for abnormalities Inspection methods that can be used by anybody Methods for actions against abnormalities

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Question yourself Seiketsu?


Are there sufficient light?
Is there noise/light in your place

causing discomfort? Do people work at designated way? Is there any leakage?

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Step 5 - Shitsuke
Step 1
Seiri Sort

Step 2

Seiton Set in Order

Step 3

Seiso Shiny clean

Step 4

Seiketsu Standardized cleanup

Step 5
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Shitsuke - Sustain
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Shitsuke
To maintain discipline, we need to

practice and repeat until it becomes a way of life

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Shitsuke
Make sure you stick to standard procedures and

make them a habit Be disciplined to follow rules and regulations to maintain standards

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Why Shitsuke?
To build housekeeping into every day process
Makes the 7 wastes visible Gets everyone involved Things to remember : Training everyone is vital Involvement from all is necessary Commitment and discipline toward housekeeping is essential in taking the first step in being World Class 5 S RATING
0= Poor (Unacceptable) 2= Satisfactory
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4= Excellent ( World Class Environment)

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Question yourself Shitsuke?


If 4S done?
Are regular 5s check conducted? Do people involved without

reminder? Do assemble at time?

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Action Plan for Implementing 5S


Awareness programme of 5s for all employees, supervisors, engineers

and managers.
Form steering committee Application programme on 5S for all Employees Steering committee periodically evaluates all cells, scores displayed on

the display board


Display posters on house keeping, distribute cards on 5S to all

employees
Annual award for the best cell
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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 Time saving Quick retrieval Accidents & mistakes minimized Increases space Creates workplace ownership Foundation of all qc tools Continuous quality improvement Lean manufacturing Visual management system Results in a place easier to manage 59

Smooth working no obstruction MGM

Checking System
Step 1
Seiri Sort

Step 2

Seiton Set in Order

Step 3

Seiso Shiny clean

Step 4

Seiketsu Standardized cleanup

Step 5
MGM

Shitsuke - Sustain
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5S Audit
Three purposes of conducting regular 5S Audit reviews are:

Review compliance to the 5S standards for your factory Note and address non-compliance to fix what is wrong! Provide a formal opportunity to suggest improvements

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The Basic Steps


Plan for the audit by dividing the workplace into various areas,

probably the same ones where different teams conducted the various 5S stages. Make a checklist for each area, based on the standards that were set during 5S. Find out the list of known problems in each area. From the initial 5S sweep, this may include:
Machines needing repair Tool racks Signage on tool racks or cabinets or storage shelves; warning signs;

keep clear markings for corridors; or instruction pages Surplus equipment or materials which were not immediately removed
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During the audit, three key tasks


ONE Determine whether known problems have been addressed:
Does this machine still leak lubricants? Has the required tool rack been installed in this area? Is it labeled? Is it

full? Are tools still left on workbenches? Is the warning sign in place so people will not walk under this crane? Why is this outdated drill press still in the corner?

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During the audit, three key tasks


TWO See that standards are being met:
Are tools left on workbenches? Is something missing from a tool rack?

Is dirt accumulating somewhere?


Are existing labels still visible and easily read? (This is especially

important for signs that may be obscured by dust, and for lines painted on floors where they can be scuffed) Are there new sounds or smells that indicate that gears are grinding or fluids are leaking?

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During the audit, three key tasks


THREE Note what has not yet been standardized this is the most creative and difficult part, because it may involve seeing what is missing in an area that seems tidy:
Why is there no sign over the neat stack of work-in-process materials

on that shelf? (How will the next shift know what is there, or what should go there?) Tools that are not yet labeled Is there a limit to how high those barrels can be stacked? Why dont we show that information on the sign for that storage area? Do we need all those cans of wing nuts in this assembly area? How many are used in one day? Should the rest of the months supply be stored elsewhere?
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Safety infractions should also be part of the 5S audit


Are WHMIS (Workplace Hazardous Materials Information

System) labels used properly? Are fire exits visible and clear? Are the fire extinguishers charged and inspected on schedule? Are stairs and ladders safe? Do we notice unsafe behavior regarding heights and falls? Climbing a ladder without maintaining three points of contact? Working on a height without the required safety tether?
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To follow up on each 5S audit


Write up a work order to deal with each deficiency
Update the next check list: Check off what was corrected Add new deficiencies to be reviewed Determine the score: Deduct for each deficiency Add a point for each correction Add a point for each suggestion for improvement If the previous audit had found deficiencies, the goal is to eradicate them The ultimate goal is to regularly achieve zero outstanding MGM deficiencies

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How often should audits be Performed?


Regular audits lead to the best results: Weekly self-check audits by teams of workers, reviewing their own areas
This might be the best way to generate suggestions for

improvements

Monthly audits by the area supervisor Ensure that the weekly audits catch any problems with the daily or weekly cleanups Pay special attention to the less-frequent cleaning tasks Try to notice what is missing: new tools that do not yet have a place in a rack; materials stored neatly but not well-labeled
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How often should audits be Performed?


Quarterly audits by the plant manager Ensure that standards are being met If there are deficiencies, ask why: try to determine the root causes Ensure that resources are allocated to repairs and to making the long-term improvements Without audits, it is impossible to ensure compliance.

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5S Audit check sheet

Model follows

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Thank you

Prepared by
M.Ganesh Murugan 9715447621
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