5S - A Program To Improve Project

2
5S – A Program to
13
45
Improve Project
Performance
Venue: Project Site Office – LSI 3 Project
Date : October 10, 2006
Quality Assurance
Objectives
Improve housekeeping 1
Make every individual responsible
2
3
for housekeeping
45
Productivity improvement by
saving time, reduced waste, space
etc.
Quality Assurance
By: Sid Calayag Version 1: Rev. 0
QAQC Manager LSI-3 Project Date: September 25, 2006 page 2
COMMON MIND SETS…
Its an additional burden. Too busy to do 5S 1
activities.
Why clean it? It will get dirty again 2
We cannot change the existing setup.
3
45
More work pressure – No time for these things
Expensive – Why to waste money?
We are comfortable – Why to change?
It will take time
Quality Assurance
So,
What’s good in 1
it? 2
3
Before we answer
... 45
Quality Assurance
Why 5S?
Look
1
Familiar?
2
3
45
Quality Assurance
So, what’s good in it again?
1
The winning companies says…
2
Work efficiency enhanced due to organized work
3
45
place
Achieve remarkable cost reduction in construction
process and improved productivity by 20%
Waste elimination, Cycle time reduction, Space
generation, Inventory reduction and improved
work ethics
Quality Assurance
Remove waste
1
Implement so that ‘waste becomes
2
visible to facilitate waste removal’
3
Waste = Current work – money generating
work
From current work remove work that does not generate money
45
Quality Assurance
5S 2
1
3
A program to help us improve
project performance 45
Quality Assurance
2 2
13
Let’s begin….
1
5S
3 4 45 Quality Assurance
Definition of 5S
(1) SEIRI (Sort)
1
2
Distinguishing between necessary and unnecessary things, and getting rid
of what you do not need
(2) SEITON (Set in Order)
3
The practice of orderly storage so the right item can be picked efficiently
45
(without waste) at the right time
(3) SEISOU(Shine)
Create a clean worksite without garbage and dust
(4) SEIKETSU(Standardization)
Standardization of best practices
(5) SHITSUKE (Sustain)
The practice of developing customs so that the workplace regulations and
rules are correctly practiced
Quality Assurance
Promotion of 5S
(1) (2) (3) (4) 1
SEIRI
(Sort)
SEITON
(set in
SEISOU SEIKETSU
(Standard)
2
3
Dispose what order) (Shine) Standardized
is not needed the solution
45
Can retrieve Make the
when required workplace
clean
(5)
SHITSUKE
(Discipline)
Develop customs that allow practice of regulations and rules
Quality Assurance
First Module
1
SEIRI 2
3
(Sort) 45
Quality Assurance
SEIRI (Sort) refers to:
Distinguishing between necessary
1
things and unnecessary things and
getting rid of what you do not need 2
3
Steps
Stratify Dispose Assign fixed place

45
Quality Assurance
‘Stratification’ refers to:
1
2
Assorting things around oneself into those
that are required and those that are not
required
3
• Other than things used daily are non-required things
• Quantity in excess of what is used daily is non-required
• ‘Leave only this, just in case’ is strictly prohibited
45
Quality Assurance
Standards Action
Frequency of Usage Dispose

1
Things used approximately once in 1 to 6 months Place in a warehouse faraway
2
3
45
Gather together in the store in
Things used once a week
vicinity of work
Place so that they are easy to pick.

Things used daily
Make it easy to return. Identifiable
Place within arm’s length where

Things used every hour
they can be easily reached
Quality Assurance
1
2
3
45
Quality Assurance
Assigning fixed places refers
to: 1
Preparing rules and making visible ‘where’
2
3
and in ‘what quantity’’ the required things are
45
to be placed
• Decide locations for things that will remain

• Make rules for locations
• Making visible refers to visual management
• Start with what can be done
Quality Assurance
Location of things that will remain 1
should consider : 2
(1) Where it will be used
3
(2) Where it will be placed
(3) How much it will be placed
(4) How it will be placed
45
Quality Assurance
SEIRI
SEIRI == Sorting
Sorting
1
2
Meaning
Meaning Distinguish
Distinguish between
between necessary
necessary and
and unnecessary
unnecessary
items
items and
and eliminate
eliminate the
the unnecessary
unnecessary items
items
3
45
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
Quality Assurance
Second Module
1
2
SEITON 3
(Set in order) 45
Quality Assurance
SEITON (Set in order) refers to :
Implementing functional storage by deciding 1
correct placement method and layout so that
2
3
the required objects can be quickly used
45
what it is required
Steps
Assign fixed places and

fixed quantity
Make it compact
Quality Assurance
Assigning fixed places and
fixed quantity : 1
Refers to facilitating picking and placing and
ensuring zero shortages 2
3
45
• Give priority to use frequency and decide fixed place
• Consider also safety (mainly weight)
• Place heavy objects at a height where they are easy to
pick from
• Eliminate labor required for searching and returning
• Decide placing volume bused on usage volume (1 time, 1 day)

Quality Assurance
Decision standards for fixed positions
1
(1) Where it will be used Clarification of usage objective and place
Near where it will be used so that work can be done
2
(2) Where it will be placed
while walking. Stand-up operations
(3) How much will be placed Maximum, Minimum, Order point
3
Easy to place, Easy to remove (one-touch
(4) How will it be placed
operation)
45
(5) Indication of placing location Coloring, boundaries
Illustrative indication, component name indication,

(6) Recognize visually
Quantity indication
First in- First out, Recognize by observing

(7) Stagnating time is visible
placement date
(8) Decide person in-charge of supervision Indicate person responsible
Quality Assurance
Seiton
Seiton == Systematic
Systematic Arrangement
Arrangement
1
2
How to achieve Systematic
Arrangement ?
3
45
• Decide where things belong
• Decide how things should be put away
• Obey the Put away rules
Quality Assurance
Seiton
Arrangement
How to achieve Systematic Arrangement ?
1
• Decide where things belong
• Standardize Nomenclature
2
3
• Determine an analytical method of storage
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• Name & locations to everything. Label both item and
location
• Store material functionally
• Prevent mistakes with coding by shapes & color
contd..
Quality Assurance
Seiton
Arrangement
How to achieve Systematic
Arrangement ? 1
2
3
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• Follow first in first out rule
• If two identical items are to be located, then store
them separately, color code them.
• Obey the rules

• Put the things back to their location after
their use
Quality Assurance
Examples of tools arrangement
(Seiton)
1
2
3
45
Quality Assurance
SEITON
SEITON == Systematic
Arrangement
1
Meaning
Meaning
that
that will
will ensure
To
To determine
ensure easy
determine type
easy accessibility
type of
accessibility for
of storage
storage and
for everyone
everyone..
and layout
layout
2
3
45
Activity - Functional storage
- Creating place for everything and putting
everything in its place
Success - Time saved in searching

Indicator - Time saved in material handling
Quality Assurance
Third Module
1
SEISO 2
3
(Shine-Clean) 45
Quality Assurance
SEISO (Shine, cleaning) refers to :
1
2
Removal of dirt and by investigating source
of dirt preparing countermeasures
3
Steps
Identify source of occurrence

Take action to prevent
dirtiness and its
occurrence
45
Quality Assurance
Actions to prevent dirtiness and its
occurrence refers to:
1
countermeasures against source of occurrence
include countermeasures (challenge towards
2
common sense) for process methods (defects in
3
45
processing conditions etc.)
• The basic point is sweeping, cleaning and inspecting

• It is also important to take immediate actions such as placing a
cover etc.
• Accumulation of small points will lead to a situation where
sweeping is not required
Quality Assurance
SEISO
SEISO –– SHINE
SHINE -- CLEANING
CLEANING
1
2
Meaning
Meaning Cleaning
Cleaning trash,
trash, filth,
filth, dust
dust and
and other
other foreign
foreign
matter.
matter. Cleaning
Cleaning as
as aa form
form of
of Inspection.
Inspection.
Activity - Keep workplace spotlessly clean
3
45
- Inspection while cleaning
- Finding minor problems with cleaning
inspection
Success - Reduction in machine down time

Indicator - Reduction in no. of accidents
Quality Assurance
SEIKETSU (Standardization )
refers to: 1
Standardization of 5S through ‘visual
2
management’
3
Steps
Grasp vital points for

management
Make abnormalities visible in
management points
45
Quality Assurance
Standardization of 5S
1
Clarification of vital points for management
- What are the minute defects
- Basic conditions: Cleanliness, refueling, replace tightly bind
2
(1)
fast, dirt, looseness
- Operating conditions: lighting, temperature, time, weight,
Equipment, jigs and tools, sub-materials
3
45
Prepare standards for the conditions
- Objectivity of judgment standards for normal versus
(2)
abnormal
- Judgment without using measurement, knowledge, intuition
and knack
Judgment standards for abnormalities

(3) - Inspection methods that can be used by anybody
- Methods for actions against abnormalities
Quality Assurance
Points for Visual Management
(1) Recognize well even from a distance
1
(2) There are indicators on items to be managed
2
(3) Whether good or bad is clear, and anybody can point out
3
(4)
(5)
(6)
Anybody can use, and convenient if used
Anybody can follow and repair quickly
Use of tools leads to neatness

45
Quality Assurance
SEIKETSU - STANDARDIZING
Regularizing 5S activities by putting systems in 1
place – Everyone does things the same way
Make it easy for everyone to identify the state 2
of normal or abnormal condition.
3
45
For maintaining previous 3S, use visual
management
5S IS EASY TO DO ONCE –
CONSISTENCY IS DIFFICULT
Quality Assurance
SEIKETSU
SEIKETSU -- STANDARDIZING
STANDARDIZING
1
2
Meaning
Meaning Setting
Settingup
upstandards
standards//Norms
Normsfor
foraaneat,
neat,clean,
clean,
workplace
workplaceand
anddetails
detailsof
ofhow
howto
tomaintain
maintainthethe
norm
norm(Procedure)
3
(Procedure)
45
Activity - Innovative visual management
- Color coding
- Early detection of problem and early action
Success - Increase in 5S indicator

Indicator
Quality Assurance
SHITSUKE (Sustain ) refers to:
1
2
Preparation of workplace atmosphere
where visual management is properly
observed
3
Steps
Check state of
observance of
standardization of 5S
Innovate to ensure
observance
45
Quality Assurance
SHITSUKE – SUSTAIN – SELF
DISCIPLINE & TRAINING
1
Make ‘5S’ is a HABIT 2
3
45
Without this, the time involved in
all the other S will be in vain.
Quality Assurance
Shitsuke
Shitsuke == Self
Self Discipline
Discipline
We need everyone to maintain 1
5S guidelines.
2
3
45
To maintain DISCIPLINE, we
need to practice and repeat
until it becomes a way of life.
Discipline is the Core of 5S

Quality Assurance
SHITSUKE – SUSTAIN – SELF
DISCIPLINE & TRAINING 1
Commitment 2
3
45
+ Everyone’s Involvement
= Success to 5S
Quality Assurance
SHITSUKE
SHITSUKE -- SUSTAIN
SUSTAIN
1
2
Meaning
Meaning Every
Every one
one sticks
sticks toto the
the rule
rule and
and
makes
makes itit aa habit
habit
Activity - Participation of everyone in developing good
3
45
habits
- Regular audits and aiming for higher level
Success - High employee morale
Indicator - Involvement of all people

Quality Assurance
The rules…
Remove fixed ideas. 1
Think of ways to make it possible.
No excuses needed. 2
Go for the simple solution, not the perfect one.
3
45
Correct mistakes right away.
Repeat ‘Why’ 5 times.
Ask ideas from many people.
There is no end to improvement.
Quality Assurance
The benefits . . .
Reduced set-up times 1
Reduce searching time
2
3
Increased floor space
Lower safety incident/accident rate
45
Less wasted labor
Higher Quality
Lower cost
Reliable Delivery
Quality Assurance
Elimination of Waste
1
5 S Element Waste/ Improvement Item Deliverable
2
Sorting-Visual Elimination of finding. Reduced Costs
Elimination of nonconformances. Increased Safety
Placement Elimination of motion. Improved Quality
Reduction of part selection errors. Increased Product Options.
3
45
Systematic Elimination of finding. Reduced Costs
Reduction of part selection errors. Improved Quality
Organization Increased Product Options
Scrubbing Clean Increased safety. Increased Safety

Preventive maintenance. Improved Quality
Increased equipment knowledge.
Standardization Increased equipment life. Improved Quality

Higher morale. Consistent Delivery
Control Clean environment. Improved Safety
Increased visibility of nonconformances.
Quality Assurance
5S Audit
1
2
Conduct an audit
3
45
to measure
improvement
Quality Assurance
Roles and Responsibility
1
2
Leaders must set the tone and lead by example.
We should commit to the initiative, Provide time to
the workforce to develop and implement 5S
changes.
3
45
Any implementation should have a drive.
Conduct short, focused and frequent
communication sessions.
Share the successes
Quality Assurance
2 2
1 13
4
Countdown begins now….
5S
3 4 5 Quality Assurance

5S - A Program To Improve Project

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2

Stratify Dispose Assign fixed place

Frequency of Usage Dispose

Place so that they are easy to pick.

Place within arm’s length where

• Decide locations for things that will remain

Success Area saved or percentage of space available

Assign fixed places and

• Decide placing volume bused on usage volume (1 time, 1 day)

Near where it will be used so that work can be done

(3) How much will be placed Maximum, Minimum, Order point

Illustrative indication, component name indication,

First in- First out, Recognize by observing

(8) Decide person in-charge of supervision Indicate person responsible

• Decide how things should be put away

• Obey the Put away rules

• Obey the rules

Success - Time saved in searching

Identify source of occurrence

• The basic point is sweeping, cleaning and inspecting

Success - Reduction in machine down time

Grasp vital points for

Judgment standards for abnormalities

Anybody can follow and repair quickly

Use of tools leads to neatness

Success - Increase in 5S indicator

Discipline is the Core of 5S

Success - High employee morale

Indicator - Involvement of all people

Scrubbing Clean Increased safety. Increased Safety

Standardization Increased equipment life. Improved Quality

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