5S - BASIC TRAINING

5S - BASIC TRAINING What is 5S and why do we want to do it? ALOK SHARMA 22\06\2010

What is 5S ? • Seiri – Sort (housekeeping) • Seiton – Systematic Arrangement (workplace organization) • Seiso – Shine (Cleanup) • Seiketsu – Standardize • Shitsuke – Sustain (Self Discipline)

What is 5S ? 5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems). These are foundational to Kaizen (continuous improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts. 5S is one of the activities that will help ensure any company’s survival.

5S 1. Sort - All unneeded tools, parts and supplies are removed from the area 2. Set in Order - A place for everything and everything is in its place 3. Shine - The area is cleaned as the work is performed 4. Standardize - Cleaning and identification methods are consistently applied 5. Sustain - 5S is a habit and is continually improved Also - Work areas are safe and free of hazardous or dangerous conditions

Some New Words Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes Some Japanese words one need to know: Kaizen-(pronounced “kai zen”) – Continual improvement Muda-(pronounced “moo da”) - waste Gemba-(pronounced “gim ba”) – workplace Kanban-(pronounced “kon bon”) - Pull type inventory control system. Items are only produced to meet customer needs. The request to produce more is signaled from an upstream operation and/or customer orders.

KAIZEN: What it is? • Process Improvement • Observation • Use of New Paradigms • Short Time • Zero Investment • Human Development & Empowerment • Profits & Savings - Plenty

KAIZEN KAI ZEN ALWAYS GOOD CONTINUAL IMPROVEMENT CHANGE FOR THE BETTER

KAIZEN IS A JOURNEY FROM: EVENT RESULT GROSS ENFORMENT OF CHANGE TO CAUSE TO PROCESS TO MICRO TO INDUCEMENT OF CHANGE

KAIZEN IS CONTINUAL IMPROVEMENT IMPROVEMENT IMPROVEMENT TIME TIME CONTINUOUS CONTINUAL

KAIZEN: KNOW THE REALITY THROUGH YOUR SENSE OBSERVATION INTELLIGENCE PHYSICAL EFFORT PARADIGM OF HIGH PRODUCTIVITY & QUALITY

KAIZEN AT GEMBA GEMBA: PLACE OF WORK • GEMBA is where . . . • Value is added • Actual work is done to meet customer requirement • Problems are solved • Staff is responsible for providing support, not for giving instruction

1. 5S Principles • Elimination of waste • Every body is involved, Co-operative effort • Attack root cause • Human being is not infallible

2. Objectives • Improve housekeeping • Make every individual responsible for housekeeping • Beautify by simple means • Productivity improvement by saving time, space etc.

SEIRI = Sorting Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items Activity Establish a criteria for eliminating unwanted items Eliminate unwanted items either by disposing them or by relocating them. Success Area saved or percentage of space available Indicator

SEIRI = Sorting Japanese Meaning : The Japanese meaning of “Seiri” is to straighten and contain. - Get rid of waste and put it in order according to rules

1 ‘S’ - SEIRI Respiratory System 1 ‘S’ – Our respiratory system sorts oxygen and other gases. And exhales other gases which are unwanted for our body

1S – SEIRI : SORTING • Sort for . . . • Not Needed at All • Needed but not Now • Needed but not here • Needed but not so much Quantity 1 ‘ S’ WANTED UNWANTED

What is unnecessary Seiri = Sorting 1. Item is not needed 2. Item is needed however quantity in stock is more than what is needed for consumption in near future 3. Contingency Parts Critically decide the quantity of contingency parts to be retained and criteria for such parts

Organization Frequency of use Storage Method Throw them out *Things you have not used in the past one year LOW *Things you have used once in the last 6-12 months Store at distance OR Keep in store *Things you have used only once in the last 2-6 months Store it in central place in your zone AVERAGE *Things used more than once a month Store it in central place in your zone *Things used once a week Store near the workplace HIGH *Things used daily or hourly Store near the workplace

Identifying unnecessary Seiri = Sorting • 1. Parts & Work in Process (WIP) • Things fallen back behind the machine or rolled under it • Broken items inside the machine • Things under the racks/ platform • Extra WIP • Stock of rejected items • Items accumulated over period for rework • Material awaiting disposal decision • Material brought for some trial, still lying even after trial • Small qty of material no longer in use Contd..

Identifying unnecessary Seiri = Sorting • 2. Tools, Tooling, Measuring devices • Old jigs, tools not in use are lying • Modified tools, tooling for trial, are lying after trial • Worn out items like bushes, liners, toggles etc. lying • Broken tools, bits, etc. may be lying • Measuring equipment not required for the operation • being performed , is lying • 3. Contingency Parts • Many times storage place for contingency parts become • a last refuge for broken parts, surplus items and things • nobody is likely to use Contd..

Identifying unnecessary Seiri = Sorting • 4. Shelves and Lockers • Shelves and lockers tends to collect things that nobody • ever uses , like surplus, broken items etc. • 5. Passages and Corners • Dust, material not required seem to gather in corner • 6. Besides Pillars and under the stairs • These places tends to collect junk, spittoon etc. • 7. Walls and Bulletin Boards • Old out dated notices which have lost their relevance • Posters or bulletins on wall • Dust, remains of torn notices, cell tape pieces Contd..

Identifying unnecessary Seiri = Sorting • 8.Floor, Pits, Partitions • Defective parts • Protection caps, covers • Packing material • Hardware items , small items • Even tools, tooling • Items dropped on the floor are never picked • 9.Computer Hard Disk • Many unwanted, outdated, temporary files pile up

Improvement methods Seiri = Sorting 1. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system e.g. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for system e.g. How to perform Seiri (sorting) 3. Check List A check sheet is used to decide what sort of main system and sub system are necessary.

Dealing with papers Seiri = Sorting How to Reduce Papers on Your Table ? 1. Make a single pile of papers 2. Go through them and sort in following categories a) Immediate action b) Low priority c) Pending d) Reading material e) For information

Dealing with papers Seiri = Sorting How to Reduce Papers on Your Table ? 4 D Principle DO DELEGATE DELAY DUMP

2 ‘S’ Seiton : Systematic Arrangement PLACE FOR EVERYTHING, EVERYTHING IN ITS PLACE Arranging things in systematic way

2 ‘ S’ - SEITON 2 ‘S’ – In our body there is a fixed place for every organ.

SEITION = Systematic Arrangement Meaning To determine type of storage and layout that will ensure easy accessibility for everyone. Activity - Functional storage - Creating place for everything and putting everything in its place Success - Time saved in searching Indicator - Time saved in material handling

SEITION = Systematic Arrangement Japanese Meaning: Dictionary meaning of Seiton is “to be correctly prepared” and “to prepare correctly”. In short these means : (a) arrange correctly in accordance with the correct method of doing activities and (b) make thorough preparations so that activities can be done even if they occur abruptly

Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide where things belong • Decide how things should be put away • Obey the Put away rules

Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide where things belong • - Standardize Nomenclature • - Determine an analytical method of storage • Decide how things should be put away • -Name & locations to everything. • - Label both item and location • - Store material functionally • - Prevent mistakes with coding by • shapes & colour • contd..

Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide how things should be put away • - Follow (FIFO) first in first out rule • - If two identical items are to be located, • then store them separately, • - colour code them. • Obey the rules • - Put the things back to their location after • their use

Seiton = Systematic Arrangement USE : 1 ) Signboards 2) Colour codes 3) Outline markings 4) Labels

Seiton = Systematic Arrangement Usage Frequency • Store frequently used material • near the workplace and less • frequently at some distance • Heavy material should be • stored at lower levels/layers • Place directly on the material • handling device for ease of • handling Weight & Shape of the Material Functional Storage

Seiton = Systematic Arrangement • Same category of material • may be stored in one location. • e.g, Allen Screws, Oil Seals Category • All items required for an • operation may be stored in • one location. • e.g, Allen key, spanner etc • hand tools required for • setting m/c Operation Wise Functional Storage

Seiton = Systematic Arrangement • Outlining and Placement Marks • - Mark boundaries of dept., aisles, Machines • - Follow straight line, right angle rule • - Nothing shall be kept outside the boundaries • Stands and shelves • - Keep only required number of • stands and shelves • - Standardize height, size • - Provide casters where necessary so that • it can be moved

Seiton = Systematic Arrangement • Wires and Ducts • - Colour code • - When there are multiple connections – • bundle the wires, label them and make sure • that they are in straight line /right angle • and firmly anchored. • Machine-tools & Tools • - Put the tools in the order you need them • - Location of the tool should be such that • it can be put away with one hand • - Try to eliminate some hand tools by • permanently attaching it to the bolt head

Seiton = Systematic Arrangement • Blades, Dies, Other important consumables • - Store them in the protected place • - Maintain these things regularly by • applying rust preventive, oiling etc. • WIP- Work In Process • - Designate a place for each component/part • - Decide on how much quantity to be stored • - Ensure that there is no damage to good part • during transit, they do not get rusty and • they are not mislabeled

Seiton = Systematic Arrangement • Oils • - Reduce number of oils used (Standardize) • - Colour code for oil • - Safety aspects - fire prevention, • pollution, leak, spillage • Instrumentation & Measuring Devices • - Label them, show direction of flow

Before sort after sort

3 ‘S’ Seiso : Cleaning KITSUI KIKEN KITENOI (DANGER) (PROBLEM) (DIRT) Clean the surroundings !

3 ‘ S’ - SEISO 3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc

SEISO = Cleaning Meaning Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of Inspection Activity - Keep workplace spotlessly clean - Inspection while cleaning - Finding minor problems with cleaning inspection Success - Reduction in machine down time Indicator - Reduction in no. of accidents

SEISO = Cleaning Japanese Meaning : Dictionary meaning “to clean up” and “getting rid of dirt and unclean items” While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection

Seiso = Cleaning • Here cleaning means more than just keeping • things clean. Cleaning should be viewed as a • form of Visual Inspection • Preventive measures should be taken to tackle • problems of dust, grim, burrs, leakage etc. • Root cause of the problem should be identified • and it should be eliminated

Seiso = Cleaning • 5 Minutes Every day for cleaning • Devote 5 minutes everyday for cleaning your • work area • Participation of everyone is required • Attack hard to clean places regularly

5S - BASIC TRAINING