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Necessity of 5S

Productivity improvement. Quality assurance. Cost reduction. Job satisfaction. Happy workplace. Secure production volume. Deadline observation. Necessity of 5S. Workplace improvement. SHITSUKE. SEIRI. SEITON. SEIKETSU. SEISOU. Definition of 5S. (1) SEIRI (Sort)

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Necessity of 5S

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  1. Productivity improvement Quality assurance Cost reduction Job satisfaction Happy workplace Secure production volume Deadline observation Necessity of 5S Workplace improvement SHITSUKE SEIRI SEITON SEIKETSU SEISOU

  2. Definition of 5S (1) SEIRI (Sort) Distinguishing between necessary and unnecessary things, and getting rid of what you do not need (2) SEITON (Set in Order) The practice of orderly storage so the right item can be picked efficiently (without waste) at the right time (3) SEISOU(Shine) Create a clean worksite without garbage and dust (4) SEIKETSU(Standardization) Standardization of best practices (5) SHITSUKE (Sustain) The practice of developing customs so that the workplace regulations and rules are correctly practiced

  3. Promotion of 5S (1) SEIRI (Sort) Dispose what is not needed (2) SEITON (set in order) Can retrieve when required (3) SEISOU (Shine) Make the workplace clean (4) SEIKETSU (Standard) Standardized the solution (5) SHITSUKE (Discipline) Develop customs that allow practice of regulations and rules

  4. Objective of 5S Remove waste Implement so that ‘waste becomes visible to facilitate waste removal’ Waste = Current work – money generating work From current work remove work that does not generate money

  5. 5S that Eliminates Waste Clean objects Dirty objects Clean objects A little dirty objects Dirty objects Waste (rag) sifting boxes

  6. “Self-discipline” is the foundation for success of 5S Seiri (Sort) Seiso (Shine) Seiketsu (Standardization) Seiton (Set in order) “Self-discipline” supports 5S Sitsuke (Sustain )

  7. Heinrich’s Law Accumulation of small details leads to big success Major accident 1 incident Small scale accidents 29 incidents Near miss / startling incidents 300 incidents

  8. Bolts Sifting and Sorting Normal 5S Standardization What value is being created ? Profitable 5S

  9. SEIRI Steps Dispose Assign fixed place Stratify SEIRI (Sort) refers to: Distinguishing between necessary things and unnecessary things and getting rid of what you do not need

  10. Stratification ‘Stratification’ refers to: Assorting things around oneself into those that are required and those that are not required *Other than things used daily are non-required things *Quantity in excess of what is used daily is non-required * ‘Leave only this, just in case’ is strictly prohibited

  11. Action Standards

  12. Categorization of Actions

  13. Assign Fixed Places Assigning fixed places refers to: Preparing rules and making visible ‘where’ and in ‘what quantity’’ the required things are to be placed * Decide locations for things that will remain * Make rules for locations * Making visible refers to visual management * Start with what can be done

  14. Location of things that will remain • Location of things that will remain should consider : • Where it will be used • Where it will be placed • (3) How much it will be placed • (4) How it will be placed

  15. SEITON Steps Assign fixed places and fixed quantity Make it compact SEITON (Set in order) refers to : Implementing functional storage by deciding correct placement method and layout so that the required objects can be quickly used what it is required

  16. Assign fixed places and fixed quantity Assigning fixed places and fixed quantity : Refers to facilitating picking and placing and ensuring zero shortages • * Give priority to use frequency and decide fixed place • * Consider also safety (mainly weight) • Place heavy objects at a height where they are easy to pick from • * Eliminate labor required for searching and returning • * Decide placing volume bused on usage volume (1 time, 1 day)

  17. Storage Index Storage index = Steps x Hand operation frequency * How many steps does it take to walk to the storage location? * How many times is it necessary to move the hand to grip, transport and place the object for storage? *The storage coefficient will vary according to holding method, transporting method and placement method

  18. Decision standards for fixed positions (1) Where it will be used Clarification of usage objective and place (2) Where it will be placed Near where it will be used so that work can be done while walking Stand-up operations (3) How much will be placed Maximum, Minimum, Order point (4) How will it be placed Easy to place, Easy to remove (one-touch operation) (5) Indication of placing location Coloring, boundaries (6) Recognize visually Illustrative indication, component name indication, Quantity indication (7) Stagnating time is visible First in- First out, Recognize by observing placement date (8) Decide person in-charge of supervision Indicate person responsible

  19. Examples of tools sorting (Seiton)

  20. SEISO Steps Identify source of occurrence Take action to prevent dirtiness and its occurrence SEISO (Shine) refers to : Removal of dirt and by investigating source of dirt preparing countermeasures

  21. Take Preventive Actions Actions to preventdirtiness and its occurrence refers to: countermeasures against source of occurrence include countermeasures (challenge towards common sense) for process methods (defects in processing conditions etc.) *The basic point is sweeping and cleaning and inspecting *It is also important to take immediate actions such as placing a cover etc. * Accumulation of small points will lead to a situation where sweeping is not required

  22. SEIKETSU Steps Grasp vital points for management Make abnormalities visiblein management points SEIKETSU (Standardization ) refers to: Standardization of 5S through ‘visual management’

  23. Standardization of 5S (1) • Clarification of vital points for management • 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 (2) • Prepare standards for the conditions • Objectification of judgment standards for normal versus abnormal • Judgment without using measurement, knowledge, intuition and knack (3) • Judgment standards for abnormalities • Inspection methods that can be used by anybody • Methods for actions against abnormalities

  24. Points for Visual Management (1) Recognize well even from a distance (2) There are indicators on items to be managed (3) Whether good or bad is clear, and anybody can point out (4) Anybody can use, and convenient if used (5) Anybody can follow and repair quickly (6) Use of tools leads to neatness

  25. SITSUKE Steps Check state of observance of standardization of 5S Innovate to ensure observance SITSUKE (Sustain ) refers to: Preparation of workplace atmosphere where visual management is properly observed

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