Qimpro Champion League:

Challenge 1: 5S

(COLLEGE LAB)

INDIAN INSTITUTE OF FOREIGN TRADE (IIFT)

Pranjal Parihar

Vivek Maheshwary

Anukriti Singh

WHAT IS 5S??? Name of the workplace organisation method

Identified as one of the techniques that enabled just in time manufacturing

5S stands for five Japanese words all starting with English letter ‘S’

Seiri (Sort)

Seiton (Set in Order)

Seiso (Shine)

Seiketsu (Standardize)

Shitsuke (Sustain)

ADVANTAGES OF 5S Reduce workflow problems.

increases product quality and productivity

Improve workplace safety

Align employee efforts with goals and strategies for eliminating waste.

1S. SORT

Separate necessary

items and the

unnecessary items

and dispose

unnecessary items

properly

2S. SET IN ORDER

Arranging all the

items in a particular

order for easy use and

reduce searching time

for a particular tool

3S. SHINE

Cleaning the

workplace and

maintaining its

appearance daily by

establishing

preventative

measures to produce

on going cleanliness

4S. STANDARDIZE

Maintain and make

the ‘sort’ ,’ set in

order’ and ‘shine’

habitual. 5S

becomes a part of

regular work routine.

5S. SUSTAIN

Ongoing application

of knowledge , skills

and abilities gained

from 5S process.

Improving

organisational

effectiveness.

5S

POOR 5S PRACTICES 1. SORT

Necessary items are mixed with

unnecessary items

Unnecessary items are lying in

the work area

2. SET IN ORDER

No differentiation between

necessary tools, equipment, etc.

Location of unnecessary items

are not clearly defined

No Designated & permanent

locations for items

3. SHINE

The area is not cleaned thoroughly

Cleaning & inspection of areas are not

taking place daily

4. SUSTAIN

No proper SOPs are there;

There is no proper documentation of

equipment & processes

No audit schedule is there

POOR 5S PRACTICES contd.

QUANTIFICTION OF THE PROBLEM

21%

16%

28%

35%

SET IN ORDER Not keeping the setup for experiments inorder

Not arrangingingstudents in group in asystematic order

Irregular sequence ofexperimentsperformed (theorylags behind praticalsessions)

Not keeping theequipemnts in properplace

47 hours Increase in time for

conducting lab experiments (monthly)

because of not following SORT. Above

reasons causing the % of time

occupied in SORT.

30 hours Increase in time for

conducting lab experiments

(monthly) by not following SET.

Above reasons causing the % of time

occupied in SET.

33%

51%

16%

SORT Searching time forinstruments

SepratingNecessary itemsfrom unnecessaryitems

RemovingUnncessary itemsfrom work area

43%

26%

31%

SHINE

Not wearing labcoats, gogglesand gloves

No daily cleaningof the floor

No regularcleaning of theworking area

16 hours Increase in time for

conducting lab experiments

(monthly) because of not following

SHINE. Above reasons causing the %

of time occupied in SHINE.

QUANTIFICTION OF THE PROBLEM

12 hours Increase in time for

conducting lab experiments

(monthly) because of not following

STANDARDIZE. Above reasons

causing the % of time occupied in

STANDARDIZE.

20%

27% 33%

20%

STANDARDIZE Not stickingquipment name onrespectiveequipments

No proper SOPs

No full time labassistants

No proper recordkeeping of theequipments

SUSTAIN:

Because of above problems, approximately 105 hours are wasted

for conducting lab experiments (monthly). It does not add any

value.

Using of 5S technique and continuously improving above, reduces

this wastage time

Effective utilization of human resources can be increase by using

this technique

QUANTIFICTION OF THE PROBLEM

RECOMMENDATIONS

1. SORT

Establish a holding area for items (Red Tag area)

Identify items not required at the current location, if at all

Team members evaluate items in Red Tag area

2. SET IN ORDER

Define the major processes (experiment) performed

For each process, draw a map of the locations of each activity

Identify sources of waste and corrective measures

Position items where they are needed based on frequency

3. SHINE

Fix leaks & other problems

Inspect daily

Fix potential issues before they become major problems

4. STANDARDIZE

Develop SOPs

Document equipment & processes

Develop audit schedule and assign tasks to individuals

Establish a methodology to ensure consistent strategy for 5S

implementation

RECOMMENDATIONS

5. SUSTAIN

Daily Checklist which looks at the cleaning of equipment and floor,

no unnecessary items, location and position of tools and storage,

condition of storage area

Weekly/Fortnightly Audit of lab by Non-lab personnel formally check

for things out of place, using same checklist

Lab In-charge: Taking Informal Walks through Lab to look for

potential problems,

A Visual Board: To Show information about & results of 5S

RECOMMENDATIONS

How to quantify the general problem in the terms of time and cost

Advantages of 5S in industry perceptive

How to identify and separate the problems.

Good 5S Practices proves to be the best if they are brought in

application.

Implementation of 5S technique in daily life .Better organize

ourselves by like pasting stickers on books to differentiate them

clearly in the rack, keeping our surroundings, room and study table

clean etc.

Utilization of resources in a effective manner

How to use bar and pie chart for quantifying the problem

Help the students to face the competitive world in future.

Working in a team and sharing and exchanging ideas with team

members.

LESSONS LEARNED BY THE TEAM

THANK

YOU