5S Training materials From Deepak Sahoo

PREPARED BY : DEEPAK SAHOO DOC. NO. : BAL/TPM/TR/5S/1005

5S Awareness

Training Program

BALASORE ALLOYS LTD.

Presented by : Deepak Sahoo

PREPARED BY : DEEPAK SAHOO B HOME PAGE - INDEX

Index

1) 5S Overview

2) Waste and Benefit’s of 5S

3) 1S - SEIRI / Sort

4) 2S – SEITON / Set

5) 3S – SEISO / Shine

6) 4S – SEIKETSU / Standardize

7) Visual Control

8) 5S – SHITSUKE / Sustain

9) Before and after Photographs

10) Feedback and Comments

Click to GO - 01 -

Click to GO - 02 -

Click to GO - 11 -

Click to GO - 15 -

Click to GO - 25 -

Click to GO - 29 -

Click to GO - 31 -

Click to GO - 38 -

Click to GO - 40 -

Click to GO - 43 -

PREPARED BY : DEEPAK SAHOO 01 GO TO INDEX SLIDE

5S - A new way of thinking for change ?

Think of the rocks and boulders as barriers because they slow

down the water flow. 5S is the first step to eliminate these barriers.

PREPARED BY : DEEPAK SAHOO 02 HOME PAGE - INDEX

What is Waste ?

Waste is anything that the customer does not look for or the customer does not wish to pay for.

All the non value adding activities are WASTE !

Non value adding activities are those , which do not contribute to the functional value of the end product.

Anything other than the Minimum amount of equipment, Material, Parts and working time absolutely essential to Production.

PREPARED BY : DEEPAK SAHOO 03 GO TO INDEX SLIDE

Ice berg analogy: > 90 % waste invisible

Waste is like a Eagle / Grave yard

Visible waste

Invisible waste


Observe this slide carefully.

Current Stage Transformation Future Stage


What is 5S?

5S is a systematic development process for creating a clean, safe and efficient workplace.

Japanese English Meaning

1S SEIRI SORT Clear

2S SEITON SET Orderliness

3S SEISO SHINE Clean and make it dust free

4S SEIKETSU STANDARDIZE Define & Refine

5S SHIITSUKE SUSTAIN Adherence


Steps of 5S.

1. Sort - Clear

2. Set - Orderliness

3. Shine – Clean and make it dust free

4. Standardize – Define & Refine

5. Sustain – Adherence


Benefit’s of 5S :-

SAFETY EFFICIENCY

QUALITY ELIMINATING

BREAKDOWNS

5 S

5 S LEADS TO CLEAN & WELL ORGANIZED WORKPLACE

5 S LEADS TO BETTER SAFETY

5 S LEADS TO HIGHER EFFICIENCY

5 S LEADS TO BETTER QUALITY

5 S LEADS TO REDUCTION OF MACHINE BREAKDOWNS


Don’t live with temp. arrangements.


Step by step implementation

NOTE : Before implementing SORT, please take photographs

of the various locations and make a note of the date.

The photographs “BEFORE” to be displayed

at that location.


Step by step implementation

UNIT :- Formaldehyde Plant Unit -4 Doc. No :- TPM/5S/B/A2/1004

Location :- Chemical Lab near SW corner

Responsible Person :- Mr. R. Kulkarni

BEFORE 5S – (20.10.2010) AFTER 5S – (DD.MM.YYYY)

? COMMENTS :- The searching time was more. Chemical storage was not proper.

COMMENTS :-


1S : SORT

Step 1

• Look around your area and make a List of all Items prevailing to that area

Step 2

• Ask your team and Yourself “ Everything here is required or not” means decide which are necessary and Unnecessary.

Step 3 • Sort out Unnecessary and Keep them in “RED TAG AREA”

Step 4 • Decide What to be done with Red Tag Area Items

Step 5 • Make a schedule for 1S.


1S : SORT

Meaning

Distinguish between necessary and unnecessary items and remove all items from the workplace that are not needed for work place.(parts, tools, equipment, etc).

Activity

Establish a criteria for eliminating unwanted items.

Eliminate unwanted items either by disposing or by relocating.

Uses RED Tag.

Success

Area Save and getting spacious work place.

Reduce the Minor accident and better Spare part management.


SORT : How we will approach ?

Decide what you need and the

frequency of the tools use.

Remove unnecessary clutter tools,

gauges, materials etc.

Remove items which are broken,

unusable or only occasionally used.

Use Red Tag for disposal.


SORT : Examples


2S : SET

Meaning

To determine type of storage and layout that will ensure easy accessibility for everyone.

Activity

Functional storage.

Shadow box, Marking.

30 Second rule

Creating place for everything and putting everything in its place.

Success

Time saved in searching

Time saved in material handling & Reduce MTTR.


2S : SET

Step 1 • Understand the frequency of usage of Necessary Item.

Step 2 • Give a Place to all Necessary Items according to step 1.

Step 3 • Give a Name and Code to every Place and Item.

Step 4 • Use Separator Line to maintain discipline .

Step 5

• Establish as many as visuals so that item can easily be tracked and placed.

Step 6 • Make sure no one can violet the discipline.


SET : How we will approach ?

SET means we arrange items so they are easy to use, and labeling them so they are easy to find and put away.

It also means operating efficiency.

Compile LITMUS TEST.

LITMUS TEST

It is also known as 30 SECOND RULE. One must locate the items

within 30 seconds.


SET : Game :: Observe it Carefully.

There are 16 tools.


SET : Game

There are 14 tools : which 2 tools missing ?


SET Game.


SET : Game

Paint brush 1

Paint brush 2

Drill M/C 1

Measuring tape

Spanner 2 Cutting wheelHammer

Torch

SawPlier

Drill M/C 2

Spanner 1

Vice

Screw driver

Plumber spanner

Horticulture tool


SET : Game

Paint brush 1

Paint brush 2

Drill M/C 1

Measuring tape

Spanner 2 Cutting wheelHammer

Torch

SawPlier

Drill M/C 2

Spanner 1

Vice

Screw driver

Plumber spanner

Horticulture tool


SET : Before & After


SET : Before & After


2S : SHINE

Clean to Inspect,

Inspect to Detect,

Detect to Correct

Correct to Improve.

Seiso (Shining)


2S : SHINE

Meaning

Cleaning trash, filth, dust and other foreign matter.

Identify and eliminate causes of dirt; find out the root cause.

Activity

Devote 5 minutes everyday for cleaning your work area

Keep workplace spotlessly clean

Inspection while cleaning

Finding minor problems with cleaning inspection

Success

Reduction in machine down time

Reduction in no. of accidents


2S : SHINE

Step 1 • Establish a Cleaning Schedule.

Step 2 • Establish the Cleaning Tools.

Step 3 • Establish the Cleaning Methods.

Step 4 • Track the abnormalities during Cleaning.

Step 5 • Strictly adhere the Schedule.

Step 6 • After two months of Practising make the Cleaning Standard.


SHINE : How we will Approach ?

SHINE means we sweep floors, scrub machines,

apply a fresh coat of paint, and then we keep

it that way.

Create a spotless workplace.

When you Sweep and Shine an area, inspect

machinery, equipment, and working conditions.

Devote 5 minutes everyday for cleaning

your work area

Find out the source of contamination.

Conduct root cause analysis to get the

sources and arrest.


4S : Standardize

Meaning

Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure).

Activity

Innovative visual management.

CLTI (Cleaning, Lubrication, Tightening & Inspection) Checklist .

Color coding

Early detection of problem and early action

Success

Increase in 5S indicator & better fault finding.

Make things easier for operator.


4S : Standardize

Step 1 • Standardise 1S, 2S and 3S.

Step 2 • Establish SOPs for 1S , 2S and 3S.

Step 3 • Develop and Establish 5S Audits and frequency.

Step 4 • Establishment of Reward system for enhancing Morale.


Visual Control

Visual Control refers to the System of Exposing Deterioration or

Displaying the Status, just by making it Visible.

Salient features:

No need to Ask, Think or Walk to get the status

Deviation should Attract the Eye at a glance

Should be Unambiguous / Universal

HER HIS


Visual Control


Visual Control

Shadow boards

ON

SPZ 1600


Visual Management


Visual Management


Visual Control in File Management

FILES NOT IN ORDER


Visual control : Examples in office


5S : Sustain

Meaning

Every one sticks to the rule and makes it a habit.

Activity

Participation of everyone in developing good habits.

Regular audits and aiming for higher level.

5S Training, 5S Competition / evaluation, 5S Posters , Literature etc.

Success

High employee morale Indicator.

Involvement of all people.


5S : Sustain

Step 1 • Ensure no one can violet Step 4.

Step 2 • Establishment of Penalty like system for not following 4S.

Step 3 • Establish the Score Board .

Step 4 • Give Regular mentoring/Coaching and Training.


Photographs for improvement

UNIT :- Formaldehyde Plant Unit -4 Doc. No :- TPM/5S/B/A2/1004

Location :- Chemical Lab near SW corner Responsible Person :- Mr. R. Kulkarni

BEFORE 5S – (20.10.2010) AFTER 5S – (28.10.2010)

COMMENTS :- The searching time was more. Chemical storage was not proper.

COMMENTS :- Chemical searching time reduced to 25 seconds. All chemicals are properly marked. 5S Score – 85.7%.


Before and After photographs


Before and After photographs


5S Review

What is 5S ?

Steps of 5S ?

What we do during SORT process ?

What is LITMUS test ?

What are the benefits of 5S ?

What is visual control ?

Difference between STANDARDIZATION & SET ?

Why it is called 5S not 6S or 3S ?

Why we take photographs before 5S implementation ?

5S : All steps ?

PREPARED BY : DEEPAK SAHOO END HOME PAGE - INDEX

Feedback & Comments !

Connect With Me @

Mobile :- +91 – 98610 15544

Email :- [email protected]

LinkedIn :- www.linkedin.com/in/dksahoo

Slide share :- www.slideshare.com/dksahoo2

Any Questions?

Education

5S Training materials From Deepak Sahoo