MOHAMMAD ANAS SIDDIQUI QUALITY MANAGER

5S AWARENESS TRAINING

25S

Declaration

35S

5’S history 5’S tool 5 principles of 5’S Review of 5’S performance 5’S audit checklist & analysis

Agenda

45S

History

o Developed by Toyota in 1970 o Is a part of Lean Managemento Is the reason behind core success

of Japan o In order to achieve high level of

quality, safety and productivity in working environment

o Eliminates waste and controls of inventory

o It completely relies on team work and individual commitment

55S

5S tool

“5S aims at creating the most effective work areas in which any deviation can be easily detected”

• Organize the workplace• Keep it effective• Detect any deviation

/hazard

• Bottom-up approach• Don’t confuse “5S”

with “Spring cleaning operation”

Key success factors

5S processObjectives

1. 1. SSORTORT

Identify necessary items and eliminate unnecessary ones

Make 5S strong in habit

5. 5. SSUSTAINUSTAIN

4. 4. SSTANDARDIZETANDARDIZEEstablish work standards, operating procedures to

maintain the work area clean

3. 3. SSHINEHINE

Make the workplace shine

Locate items where they are

needed

2. 2. SSET IN ET IN ORDERORDER

5S

65S

Principle’s of 5S

1. Sorting – Separating the needed from the not-needed

2. Set in order – A place for everything and everything in its place, clean and ready to use

3. Shine – Cleaning for inspection

4. Standardizing – Make up the rules, follow and enforce them

5. Sustaining – Holding the gains and improving

75S

AFTER BEFORE

Office/lab area

Work station

Example of 5S illustrations

85S

1. Sort

Clear out, Classify and Identify :• The things you definitely need all the time• The things you definitely need occasionally• The things you might need in the future• The things you no longer need

*****Never Assume*****

Ensure that every one is in agreement

95S

Example for Sort

BEFORE AFTER

Examples of labeling

Pink :

Need All The Time

Green :

Need Occasionally

Orange :

Might Need in Future

105S

2. Set in order

Put everything in its correct place• Organize storage for all equipment

• Frequency of use, defines location relative to point of use

• If it is used frequently keep it close/low frequency store offline

• All essential such as fire extinguishers and safety equipment must be visible and easily accessible

“ A place for everything and everything in its place”

115S

Example of Set in order

Frequently used tools to be keep Closer

125S

3. Shine

Clean and Check• Create a clean and tidy working

environment and maintain it

• Define responsibility zones for cleaning areas and responsibilities

• Develop regular routines for maintaining a clean environment (e.g. 5 min. 5’S’ etc.)

• Cleanliness is the basis of quality. Once the workplace is clean it must be maintained

135S

It’s just a basic housekeeping of desk, computer and daily utilized belonging

Example of Shine

BEFORE AFTER

145S

4. Standardize

Conformity :• Design clear, standard labels for locations, tools, machine

conditions and locate them in standard positions

• Provide indicators where limits can be exceeded

• Draw position markers in places where items are removed and returned

Agree and set :• Standards of cleanliness.

• Procedures for maintaining standards

155S

Example of Standardize [1]

BEFORE AFTER

165S

Orange stripes shows limit & Yellow shows Location for Bottle

Example of Standardize [2]

175S

5. Sustain

Adhere to the system rules• Develop and maintain habits through training and discipline. (At all

time)

• Use visual rather than verbal communication to train for new procedures

• Involve everyone in the development of standard documentation.(e.g. Check sheets etc.)

• Be conscious of time ( 5-10 min. 5 S)

It is important to maintain discipline• Incorrect practices must be identified

• Correct practices have to be taught and demonstrated

• Ensure everyone’s understanding and agreement

185S

Example of Sustain

BEFORE AFTER

195S

Regular audit Continual improvement through regular follow up and

individual commitment Tracking of performance through each audit Review of performance through Management head

Review of 5S performance

205S

5S audit checklist and analysis