5S Methodology

Work Environment - (5S)Work Environment - (5S)

1S - SEIRI - SEGREGATION

2S - SEITON - SYSTEMATIC ARRANGEMENT

3S - SEISO - SPICK & SPAN

4S - SEIKETSU - STANDARDISING

5S - SHITSUKE - SELF DISCIPLINE

A SOURCE OF PRIDE


Products /Services

MaterialsMachines

MenMethods

CustomerSatisfaction


SEIRISEITON

SEISO

SEIKETSU

SHITSUKE

SSS


What are 5S ? 5S stands for five good housekeeping principles.

5S becomes a base for continuous improvement.

5S principles are very effective systematic approach for improving our work environment and total quality.

5S are participation programme.

5S is based on the belief that every individual can contribute to improve his/her workplace where he / she spends one third of his / her life.

Objectives of - 5SObjectives of - 5S

• Creating a neat and clean workplace.

• Systematize day to day working.

• Improve work efficiency.

• Standardize work practices.

• Improve work discipline.

• Improve productivity.

• Improve quality.

What do we get from practicing 5S What do we get from practicing 5S activities ?????activities ?????

1. All working area in proper order.

2. Create more vital working atmosphere.

3. Cheerful / good mood.

4. Safe environment.

5. Higher work efficiency.

6. Create work effectiveness.

7. Take Pride.

1. Increase production efficiency.

2. Reduce unnecessary work.

3. Low production cost.

4. More space and storage are obtained.

5. World class company is expected.

6. Obvious factory.

7. Confidence and recognition are obtained.

Employee Organisation

5S5s

1S - SEIRI - SEGREGATION1S - SEIRI - SEGREGATIONSEIRI means to distinguish between what is necessary and what is unnecessary in accordance with specific rules and principles and get rid of what you do not need.

Saving things and information which

one does not need consume extra space and

create more wok.

SEIRI is excellent way to gain valuable floor space

and eliminate scrap and excess raw material.

1S - SEIRI - SEGREGATION1S - SEIRI - SEGREGATION

Throw away / get rid of

Put for sale

Place in the right location and identify with tag

Unnecessary things with no value

Unnecessary things with value

Things still used and needed

Acceptable product mixed with reject

Reject mixed with acceptable one

Lost and Waste

Lose Brand loyalty

Customer does not pay for waste.

What is the criteria to distinguish necessary and unnecessary ?


Clarify standards to judge the necessary things from the unnecessary.

Segregate the things in compliance with the set standard.

Extended decision making is prohibited.

Schedule the itinerary checking by promotion committee members.

Eliminate the space to store unnecessary things in order to expel such things.

Do not hurry to expand the space.

The goods which cannot be sold are unnecessary.

How to implement SEIRI - 1S ?


Where unnecessary things can be found ?

Shelves & Lockers - surplus/broken articles

Passageway and corners- useless articles

Behind pillars and under stairs- materials, defective

Warehouses and sheds- materials/in process articles

Walls and bulletin boards- expired notice

Behind and also under the machines-broken articles

Under the floor and side ditches- scrap

Materials and in process articles

Outskirts ( Near the wall, fences, and drainage)

1S - SEIRI - SEGREGATION1S - SEIRI - SEGREGATIONBenefits from SEIRI

•Eliminate the excess use of space.

•Eliminate the excess equipment.

•Eliminates the excess use of file cabinet / shelf.

•Eliminates accidents.

•Eliminates errors.

•Eliminate waste of time

•Reduce cost of production.

2S - SEITON - SYSTEMATIC 2S - SEITON - SYSTEMATIC ARRANGEMENTARRANGEMENT

SEITON means having things in the right place or right location. It is for the most efficient and effective retrieval. Make a system which enables anyone to take out the thing promptly.

“A place for everything andeverything on its place”

What to do with segregated necessary things ?


How to implement SEITON ?

Fix the storage space.

Clearly indicate the storage location.

Unify the names of thing.

Stratify things.

Things which are used once or twice a year --- to be stored in remote place.

Things which are used about once a month --- to be placed collectively in the work place.

Things which are used daily --- to be placed within the work area.


Decide how to put things.

In relation to quality.

Avoid placing the things which resemble each other together. Show the difference clearly.

Indicate the storage period.

Use the first in first out method (FIFO).

Distinguish clearly between good and inferior quality goods.


Establish a storage standard.

Being taken away--- Who did it, when is the return date?

Out of stock--- Is there backup supply?

Stock replenishment---Who places an order, to whom and for what quantity.

Way of eliminating the unproductive time spent in looking for necessary things.


Decide how to put things.

In relation to efficiency.

Assigned place marking, putting things visibly in place.

Location --- self numbers

Layout --- minimization of movement.

Ease of removal and storing.

In relation to SAFETY

Put heavy weights at lower place.

Prevent overturn and drops.

2S - SEITON - SYSTEMATIC ARRANGEMENT2S - SEITON - SYSTEMATIC ARRANGEMENT

Benefit from SEITON

Helps to reduce time for finding useful material .

Create work effectiveness.

Create safe atmosphere.

Easy to inspect and recognize when material are gone from their location.

3S - SEISO - SPICK AND SPAN3S - SEISO - SPICK AND SPANAre floors and machines cleaned for the sake of

appearance????

SEISO means getting rid of waste, grime and foreign matter and making things clean. Make a system which eliminates the cause of dirtiness.

CLEANING AS A FORM OF INSPECTION.

3S - SEISO - SPICK AND SPAN3S - SEISO - SPICK AND SPAN

CLEANING IS A EVERYBODYBUSINESS.

WHY to do SEISO ?

SEISO ( Cleaning) is a philosophy and commitment to be responsible for all aspects of the things you use and to ensure that they are in tip top condition

Dust, dirt, grime, foreign matter etc. are looked upon as the prime causes for unexpected failure of equipment, unhygienic environment and even accidents.

Therefore SEISO should be viewed as way to eliminate these problems one by one.

3S - SEISO - SPICK AND SPAN3S - SEISO - SPICK AND SPANHow proper cleaning to be done?

Following steps to be followed for doing proper cleaning:

Measures against the root of uncleanliness.

Investigation of the root of uncleanliness.

Measures against the cause of uncleanliness

Prevention of leakage

prevention of scattering

prevention of falling

study of manufacturing method

Correct looseness

3S - SEISO - SPICK AND SPAN3S - SEISO - SPICK AND SPAN How to deal with places which cannot be cleaned easily ?

Devise effective means to collect and dispose of dust.

Review of dust collection capacity and method, cleaning equipment and method of washing.

Cleaning of workplace

Allotment of areas and equipment to be cleaned

First allot the area by group, then allot a related job by person.

Do Cleaning

Detect abnormal condition while cleaning.

Establish cleaning rules.

Decide when to do cleaning.

3S - SEISO - SPICK AND SPAN3S - SEISO - SPICK AND SPAN Cleaning of equipment

Do cleaning by a check sheet.

Wipe out dirt.

Cleaning of clogged filters, pipes etc.

Control of generation of heat and other temp.

Correction of displacement.

Teaching of equipment and facilities element

General equipment and facilities check point

Check point for cleaning.

Check points for oil

Check points for additional tightening

check point for temperature control

check point for breakage.

4S - SEIKETSU - STANDARDIZE4S - SEIKETSU - STANDARDIZEWhat do you mean by

“SEIKETSU”

Seiketsu means continually and repeatedly maintain 1S, 2S & 3S standard achieved. Make a system which enables quick detection of a disordered condition / state.

It must be made possible for anyone to see the actual

situation at a glance by means of“the visual control”

4S - SEIKETSU - STANDARDIZE4S - SEIKETSU - STANDARDIZEHow to maintain 1S, 2S & 3S ?

Standardization is a condition where the segregation, Systematic arrangement and Cleaning have been repeated and maintained. Introduce extensive visual controls so that abnormalities show up by themselves.

Following steps to be followed to maintain and promulgate first three “S” more deeply.

Points of visual control

Standards for what is good and bad are clear.

Abnormal conditions are shown.

4S - SEIKETSU - STANDARDIZE4S - SEIKETSU - STANDARDIZE Tools of visual control

Label - lubrication label, accuracy label, inspection label, label showing the person incharge, equipment number and category.

Limit marking - meter zone, stop line, assigned place marking, danger alert.

Visualization - Status indication, direction indication, maintenance display board, Instructions, colour code for pipes, picture of safety gadgets to be used in the area, direction sign for emergency points & fire extinguisher, Caution and operation reminders.

4S - SEIKETSU - STANDARDIZE4S - SEIKETSU - STANDARDIZE

PREVENTS THE 1S, 2S AND 3S RETURNING TO 0S !!!!! PROPER AND NICE WORKING AREAS. STANDARD OPERATIONS AND PROCEDURES. CREATE EXCELLENT PHYSICAL AND MENTAL HEALTHS.

IT MEANS HAVING THE ABILITY TO DO THINGS THE WAY THEY ARE SUPPOSED TO BE DONE. THE EMPHASIS IS ON CREATING A WORKPLACE WITH GOODHABITS AND DISCIPLINE.

Doing the right things as routine.

5S - SHITSUKE - SELF- 5S - SHITSUKE - SELF- DISCIPLINEDISCIPLINE

Discipline means to get accustomed to the operation in compliance with standards. It is the discipline to honour faithfully the promises agreed upon by the fellow people.

The purpose of “SHITSUKE” is to support the four “S” ( Segregation, Systematic arrangement, Spick & Span and Standardizing) as the means to satisfy such fundamental things.

Keep practicing the activitiesthrough those procedureuntil they become habits.


Discipline means thinking about the many problems that occur day to day and resolving to do better.

People sometimes make the most unbelievable mistakes because they let their guard down- because they forget their discipline.

“Practice and more practice.”

When you assume that somethingis easy just because you have

done it thousand of times, that iswhen you are most likely

to get it wrong.


How to instill discipline ?

1) Cultivation of habits

• Make clear what should be done.

• Do it every day with the participation and practice by every one.

2) Conduct training

• Train employees until they become capable of complying with standard.

• Make worker responsible for action and not for the results.


It is very important to practice and more practice, because practice reinforces correct habits.

It is very important to be strict about how things are done - even the little things.

Disciplined workplace is the mostimportant thing to ensure

“ Product Quality”

Documents

5S Methodology