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Necessity of 5S
Job satisfaction
Deadline observation Happy workplace Secure production volume
Workplace improvement
SEIRI SEITON
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The 5 Words
Step 1
Seiri Sort
Step 2
5S is a method that uses five Japanese words which start with the letter S
Step 3
Step 4
Step 5
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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
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
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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
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Reasons to implement 5S
Improved Safety
Fewer break downs Better work Environment
A clean & well functioning workplace
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
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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&
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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
Step 3
Step 4
Step 5
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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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Step 1
Seiri Sort
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Step 1
Seiri Sort
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Step 1
Seiri Sort
longer in use
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Step 1
Seiri Sort
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Step 1
Seiri Sort
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Step 1
Seiri Sort
Seiri Sort
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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
Step 1
Seiri Sort
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Waste elimination
Try to identify every thing that is
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
What measures do we need to
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
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
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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
5S Sort list
Every tag refers to a 5S Sort list
Step 1
Seiri Sort
Tag no
Item description
Session tagged
Date
Tagged by
Responsible
Due date
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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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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
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
Frequently used
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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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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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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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ink?
Are shades, lights, bulbs, and light
reflectors dirty?
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Step 2
Step 3
Step 4
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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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Step 5 - Shitsuke
Step 1
Seiri Sort
Step 2
Step 3
Step 4
Step 5
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Shitsuke
To maintain discipline, we need to
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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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and managers.
Form steering committee Application programme on 5S for all Employees Steering committee periodically evaluates all cells, scores displayed on
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
Checking System
Step 1
Seiri Sort
Step 2
Step 3
Step 4
Step 5
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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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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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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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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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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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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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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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Model follows
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Thank you
Prepared by
M.Ganesh Murugan 9715447621
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