Chapter 1 Introduction Nowadays many companies are going into 5S implementation to enhance their company’s productivity and reduce
wastage. Through the implementation of 5S the companies can move forward and being more competitive in the future. In 5S it promoted continues improvement in daily activities, so this will foster the effectiveness and efficiency of work flow at work place. It encourages positive working attitudes and teaches employees become more discipline. It also becomes the hallmark for the companies to represent “good housekeeping” and embarking towards lean journey. 5S is not a complex system; it is the simplest system which is has 5 philosophies that need to be followed. The most important things are cooperation and commitments to achieving and sustain 5S implementation. 5S is originally comes from Japan and being develop by Hiroyuki Hirano who is just-intime expert and international consultant. The approach of the implementation of 5S is it controls the work floor conditions rather than the employee’s behavior. The workers itself need to ensure their work station or workplace is according to the 5S principles. Beyond the 5S implementation, it encourages proactive approaches that prevent problems and waste before occur and worsen. There is no chance for efficiency or quality improvement within dirty work place, waste of time and scrap, that why companies needed 5S to eliminate this things. The basic assumption states "wastes are potential gain, eliminating wastes is a gain". It is inexpensive for the company to implement and it makes the employee’s job easier and safer. Thus it also can reduce the potentially accident from being happened. This good housekeeping approach can lead to a smoother running operation and enhance the productivity of companies. It is a series of improvement models to create a faster, better way of working without high cost and maximizes efficiency. The 5S philosophy is generally focusing on effective work place organization, simplified work environment, strive waste reduction while improving quality, team work and safety. It provides a practical method for dealing with the real problems that employees face every day.
The 5S philosophy is referring to the principles of continues improvement in the workplace. The philosophy of 5S principles are: seiri, seiton, seison, seiketsu and shitsuke when it been translated into English, start with letter “S”. The meaning of 5S in when it been translated in English are: sorting, straightening, systematic cleaning, standardizing and sustaining. Sometimes, there are two other principles included, which is safety & security to strengthen the 5S philosophy. Why almost in the world trying to implement 5S in their organization structure? The reason is 5S show efficiency in time, transforming the physical environment of work area and spirit of all employee levels. Thus it will motivate the employees to work hard in a safe, clean and organize working environment. These terms can be described as follows:
1. Seiri or Sort is the first step in the process and mandates that necessary items
are kept within the workplace. Useful, but less often used, tools and items are delegated to storage. Unnecessary items or waste are tossed out. This will create a leaner but more efficient operating space. Recommended way of sorting is to take the workspace and red tag all items not needed to complete the job. These items are moved to a central location and from there deemed necessary or waste. This clears a workspace of broken, obsolete or "just in case" items. 2. Seiton or Systematic Arrangement is the next step and allows for the organization of needed tools and equipment in the right places. This is the what, where and how of each job. Decide what is needed, where it is done, and how many are needed. Tool carts that provide needed tool sand equipment are a great example of seiton. Defining work areas is also part of this step. 3. Seison or Sanitary demands cleanliness. For some establishments this means a thorough cleaning first, and then follows up with a regimen of daily cleaning tasks to maintain a sanitary environment. By keep equipment and areas clean, the lifespan can be extended and maintenance issues can be detected earlier. This also creates a safe work environment.
Seiketsu or Standardizing requires SOP. make sure they are informed. and post them visibly in the workplace to serve as a reminder of the goals. Communication is a key component in implementing standard procedures.com)
. reinforcement of
goals and adjusting procedures that become outdated and no longer work.
5.4. helium. or standard operating procedures. Shitsuke or Sustain the program needs continuing education. more efficient workplace ( Teresa Aira. These will support and maintain the effort put forth in the first three steps of the process and is key to keeping the program vital. Develop them with input from employees. This gives credence to the program and is the backbone of maintaining the goals of a better.
2003. Focus Our experienced pool of people are fully dedicated with their core competence and committed to deliver only the best products and services to our customers. Innovate Our dedication and commitment to deliver only the best products and services demand continuous creative and innovative working process for improved value to our customers. Maces is an ISO 9001:2000 certified plant since 2004 and assured the customers with the highest quality product delivered all the time. Strategic Mission Deliver the essentials of life. This company consists of a group of specialists which have integrated both the chemicals capabilities along with engineering capabilities. Execute Our creativities and innovations are practical and realistic that all solutions are deliverable and meeting customer specific needs. every time.
. experienced people with extensive knowledge of the industry and their ability to apply the right technology to provide you value added solution. Its key strengths lie in its highly trained. The motto of MACES is Focus. Innovate and Execute. Strategic Intent One-stop center for chemicals and water management needs with local expertise meeting world class standards. protect the environment and contribute to the community.Company Background Maces Sdn Bhd (Malaysian Chemicals And Engineering Services) was incorporated under Malaysia Companies Act 1956 on 12th March.
activities. From this study we can know how effective and proactive their 5S implementation and is that they can sustain 5S in the future.
. Even MACES try delivered the best strategy. Besides that to determine the most significant factor that has strong influence towards 5S implementation and sustainable. Thus it can improves and sustain 5S implementation the future.Background of Study The purpose of this study is to figure out of the implementation of 5S at MACES. the main problem of MACES is that their employees are giving fully commitment towards 5S implementation and is that their employees are aware and giving fully cooperation to achieve 5S standard at MACES. Problem Statement Based on the background of study. This will help MACES to overcome the problem and eliminated it. The researcher chooses commitment and awareness. Besides that through this study also major problem can be identify. consistency of implementation and promotional activities and practices at MACES. Objective of Studies The objective of this study is to figure out the implementation and sustainable of 5S based on commitment and awareness. consistency of implementation and promotional activities and practices as a subject to be studied to identify is that this thing is the major influences that would be effected to the implementation and sustainable of 5S implementation. The researcher will be analyzed and identified the major problem and try to come out with suitable solution towards to sustain 5S implementation. programme etc to ensure the successfulness of 5S implementation but still can’t achieve the target and goals.
• To help MACES to find out the major problem that causes to the unsuccessfulness of implementation and sustainable of 5S. The data can be obtained through secondary data. Significance of Study • To understand which the most important factors that influences the implementation and sustainable of 5S at MACES. consistency of implementation and promotional activities and practices towards the implementation and sustainable of 5S. To complete this research lot of data and interview session needs to be gathered to ensure the information that been obtain is accurate.Scope of Studies The scope of this study is to investigate the influences of commitment and awareness.
. This research will measure the relationship of commitment and awareness. consistency of implementation and promotional activities and practices that is contribute to the successfulness and sustainable of 5S implementation at MACES. • To help MACES to improve and know the weakness of their implementation and sustainable of 5S. .
Rosmaizura Mohd Zain. fully understood and addressed (Mohd Nizam Ab Rahman. It is a concern of everyone to act. the employees haven’t captured the 5S implementation properly and are not able to standardize the 5S’s activity. the 5S’s practice is a technique used to establish. Pheng. Organizing the 5S’s team is an important approach in solving many potential problems.. All level of management should take part in decision making required to ensure 5S’s implementation. 2007). The 5S’s will not be taken seriously until the managers and even the company president take personal responsibility and interest on its implementation (Noeradji Prabowo. As suggested by (Ho. (Jim Parrie.
.2009). The full benefits of the 5S’s cannot be experienced in the business sector until all the obstacles associated with implementation of the technique are recognized.2009). Commitment is not possible without top management's visible support for the program. The success of the system requires the recognition of all these operations by everyone and its continuous observation. 5S’s program will be short-lived. Hill. maintain quality environment in an organization effectively and promised the employees to be more self-discipline (Ho. Incorporate 5S’s activities as part of company’s small group activities (Noeradji Prabowo. Without proper training. Nor Kamaliana Khamis.2003). It is really about developing a culture that insists on employees thinking and acting in a disciplined way to keep their work areas organized and visible (Arthur V.2009). 1999a. Another important factor required for its successful application is that everyone has “teamwork soul”( Korkut et al. If entire organization is not committed. All employees must believe that the organization is committed to the program. 2001). In the other hand. training is the 5S’s key of success.2003). 2010).Chapter 2 Commitment and awareness of 5S’s 5S’s is not being the responsibility of a concerned few. Hill. A visual work area provides cues that help workers and supervisors immediately know the current status of the system and quickly identify if anything needs immediate attention (Arthur V.1999). Baba Md Deros and Wan Hasrulnizzam Wan Mahmood.
the employees haven’t captured the 5S implementation properly and are not able to standardize the 5S activity. 5S is an approach that can be easily applied in all organizations.as supported by (Gapp et al.. Nor Kamaliana Khamis. The most significant barriers identified are related to lack of communication and gap between the top management and shop floor employees and also the lack of training and consciousness of this activity amongst the staff. no one is an observer and continually repeat the 5S’s cycle order to reach higher standard (international labor organization. Baba Md Deros and Wan Hasrulnizzam Wan Mahmood. Its simplicity and easy recognition is the superior side of 5S (Korkut et al. 2008).Involve everyone. it should have reached to a total quality culture developed as to not cause any problem regarding the success of the recommendation and opinions coming from sub-departments and workers (Karabulut.2009). Most Japanese companies claimed that the 5S benefit is not only for improving their physical environment.2009). and removing items of little or no value (Arthur V. (Warwood and Knowles. 1999). Baba Md Deros and Wan Hasrulnizzam Wan Mahmood. but also improving their thinking processes as well. Rosmaizura Mohd Zain. time. Continuous assessment in both companies is believed one of the key drivers to changing the culture of the organization (Mohd Nizam Ab Rahman. Workers and management at all level must take responsibility to keep their work area clean and orderly if 5S’s is to be achieved (international labor organization. Without proper training.e. Nor Kamaliana Khamis. Begin to develop a disciplined culture of keeping the work area up to 5S standards at all times. Poor communication will influence the poor results in managing the resources i.
. Hill. Rosmaizura Mohd Zain. 2008). budget and materials with resultant lowered morale and motivation amongst employees (Mohd Nizam Ab Rahman.Everyone in the organization must be fully committed to implementing the 5S’s process. 2010). making sure that everything is always in the right place. 2004) stated that the implementation of 5S is tended to depend on the stage of the 5S programme. This involves developing the habit of always putting things back in the proper place. 2010). Furthermore. 2008).
get started stick with it (Noeradji Prabowo. Grout (2009) argues persuasively that 5S is a good starting point for process improvement.2003). Don’t stop with 5S: Follow through with zero defects. 5S is far more than just keeping a work area clean. quality. 2010). Hill. cannot get people to agree on the process design. and labor productivity. and other productivity and quality improvement (Noeradji Prabowo. 5S is a simple and effective lean methodology that helps organizations simplify. The results of a good 5S program include improved visibility.2003). along with reduced waste. He argues further that if an organization cannot do 5S. Get management approval for all 5S activities (Noeradji Prabowo. Forming a ground for the other improvement activities.
. It is really about developing a culture that insists on employees thinking and acting in a disciplined way to keep their work areas organized and visible (Arthur V.2008). it cannot keep its work areas clean. cost. Hill. 2010). 5S approach forms the basis of the other improvement activities conducted at the company and leaves positive impact on the motivation of the personnel (Sarıcoban. safety. morale. Once 5S promotional organization methods have been established. A place for everything – each thing in its place” is one of the basic rules in the implementation of the 5S system. and sustain a visible and productive work environment (Arthur V.Consistency of 5S’s Implementation 5S activities should not be performed in a secret or disguised such as overtime work. 1997). as well as safety standards in a systematic way. and cannot implement standards.2003). cost reduction. cycle time. The 5S system of rules is based on order and discipline within all departments involved in the manufacturing of exhaust systems (Gheorghe Dulhai. environmental performance. 5S is an important term that carries priority in improvement at a company (Celebi. O’hEocha (2000) confirmed that 5S is an effective technique that can improve housekeeping. clean. increased revenue and increased profit (Arthur V. Don’t do things halfway. Ultimately. 2010). a good 5S program will result in lower cost. Hill. and an increased sense of ownership of the work area. 2006).
The 5S auditing criteria must be relevant to the business nature or working environment. D.In Malaysia. 2007). The 5S method begins each programme of improvement. 5S audit could be categorized as a crucial tool to ensure that the accurate deployment of 5S in an organization (Ho. (Ho and Fung.. Baba Md Deros and Wan Hasrulnizzam Wan Mahmood. 2010). 1994) stated that 5S is one of the strongest tools for enhancing the success factor of TQM implementation. Even a smallest levity that may form during the training challenges the achievement of expected results. 1999). 2003). The 5S concept is applicable for many industry types or business natures. The audit process of the study place. Rosmaizura Mohd Zain. Rosmaizura Mohd Zain. Nor Kamaliana Khamis. 5S is a system applied for providing order and discipline at companies. Michalska. the Standards and Industrial Research Institute of Malaysia or SIRIM has played an effective role to encourage the utilization 5S concept among Malaysian industries (Ho et al. 2010). (Ho. then the targeted objectives are achieved in a faster manner (Korkut et al. provides the supervision of both simple and even the smallest details of the company and forms the basis of the other improvement activities (Erdal. Nor Kamaliana Khamis. it enables each organization to identify the potential level of quality improvement in real situation (Mohd Nizam Ab Rahman. It is the tool for helping the analysis of processes running on the workplace (J. These kinds of studies should be continuously supported by the planned training programs (Sevim Korkut and Erdinler. as well as align with organization policy and vision (Mohd Nizam Ab Rahman. A successful 5S application is dependent on the trainings to be provided by the directors to the personnel. Baba Md Deros and Wan Hasrulnizzam Wan Mahmood. including service sectors. 1995).
. 1999) found that most of operating companies in Hong Kong has successfully improved quality of product as well as increasing the working life underneath of 5S deployment.. Szewieczek.2009). In case if 5S awareness is combined with the work. 2007).
Present actual example of successful of 5S implementation. 2004). 2004). Understand 5S as we understand all aspects of other types of improvement and problem-solving activity and then to agree a change programme for our own business (Ian Henderson. providing top management feedback and going to bat for 5S if needed (Christopher D. 2007). Organizations should also consider engaging informal shop floor leaders by utilizing 5S coordinators. perhaps by printing posters or signs that can be written on as important quotas are met (Nilesh R Arora. It is important to find a visible way to measure your progress. or take participants on tour to successful 5S workplace (Noeradji Prabowo. Chapman. who are volunteers charged with harmonizing. Company managers must take a strong leadership role in 5S promotional meetings and other 5S event (Noeradji Prabowo.5S Promotional Activities and Practice The elements of 5S are all valuable in their own right but they simply form part of the bigger picture of establishing best practice (Ian Henderson. 2004). Identify what is to be done. 2005). The history and culture of the company or the specific plant have to be taken into account when this decision is taken(Ian Henderson. 2007). Management should endorse the formal 5S plan and set dates for implementation (David McBride. and ensure that schedules are updated and clearly visible (Ian Henderson. Chapman. As employees grow into the 5S system. 2007). Organizations with successful 5S programs measure their performance with weekly audits using checklists and score sheets (Jim Parrie. The employees doing the day-to-day maintenance of 5S. Conduct a general monthly meeting where company and managers can address the issues and themes (Noeradji Prabowo. People tend to resist change and even the most well structured 5S plan will fail if not constantly reinforced. .2003). Catch phrases and slogans can be used to make sure no one forgets the significance of your goals (Nilesh R Arora.2003). 2003).2003). rewarding for everyone involved. Look for ways to emphasize the positive results of a 5S program. 2005).
. the will find it energizing and fulfilling (Nilesh R Arora. 2007). monitoring and leading implementation (Christopher D. 2004). a designated management champion should be responsible for visibly supporting the process. by whom.
2003). well-ordered workplace that is the foundation of improvement (Oakland University Pawley Learning Institute. Set of techniques providing a standard approach to housekeeping within Lean Manufacturing (Ian Henderson. 2007). This document contains a translation of those words and their corresponding meanings in the English language (Nilesh R Arora. and shine everything around the work area. self-improving. wash. commitment.What is 5S The 5S philosophy focuses on effective workplace organization and standard work procedures. self-ordering. • Set in order (straighten. The Japanese characters for 5S are (Chu. and accountability. scrap. 2009): • Sort (separate. clean. and sustain a visible and productive work environment (Hill. sift) – Separate the necessary and unnecessary items and get rid of the unnecessary items. 5S is a process of work place organization and housekeeping carried out gradually and systematically (Noeradji Prabowo. 2010).
. self-discipline) – Ensure that all 5S policies are followed throughout the entire organization by means of empowerment. • Sustain (systematize. • Standardize – Use standard methods to maintain the work area so it is visible.2003). The method is a structured program to implement workplace organization and standardization. A well organized workplace motivates people. A good 5S condition is a clean. The 5S visual management system is designed to create a visual workplace – a work environment that is selfexplaining. and in a constant state of readiness. It is based on five Japanese words that begin with S. 2004). both on the shopfloor as well as others (Noeradji Prabowo. • Shine (scrub. 2006). clean. clean. store. simplify) – Organize the work area and put everything in its place. 5S is a simple and effective lean methodology that helps organizations simplify. sweep) – Sweep.
2007). Organizing the 5S team is an important approach in solving many potential problems. The 5S is the methodology of creation and maintaining well organized. seiketsu (standardization) and shitsuke (discipline) (Ho et al. capital and time to make products with fewer defects. a business system for organizing and managing manufacturing operations that requires less human effort. high effective and high quality workplace. It creates a work environment that is disciplined. Ho.The 5S is the acronym of five Japanese words which stands for seiri (organization). seiso (cleanliness). clean and well ordered (Christopher D. In the other hand. Michalska. 2001). Pheng. Sui-Pheng and Khoo. D. 2005). improvement of the quality and safety of work (J. elimination of losses connected with failures and breaks. reduction of work’s environment. 1999. clean. Szewieczek. 5S is systematic and organic to lean production.. Chapman.
. space. 1995. seiton (neatness). 2001). 1997. Its result is the effective organization of the workplace. maintain quality environment in an organization effectively and promised the employees to be more self-discipline (Ho. the 5S practice is a technique used to establish.
Even the top management had advise the employees to gave the cooperation to ensure the successfulness of 5S systems but these cooperation and team work are long lasting been performed by employees. the top ranking people also involve actively in the implementation of 5S. The participation of all MACES employees would be better to find out the solution. That why it become hardest part to changes the work culture and environment in the company. At least even the ordinary employees can come out the brilliant ideas to solve these matters.
. They only care about their job scope only. It can be start to changes the simplest one first until face it the hardest part. This is because certain company is comfort with ordinary work culture. effective management system. In order to implement 5S systems at MACES. In the 5S even the top ranking in the company also need to involve showing good role models to their employees. These problems need to be solve immediately to ensure the successfulness of implementation and sustainable of 5S systems at MACES. The main problem that always been come out in the 5S implementation is cooperation and team work among MACES employees. discipline etc. there are several problems that incur according to the MACES employees opinions. By doing this their employees will be automatically feel embraces if they are not involve and giving up the cooperation towards this programme. cooperation. Cooperation and team work is important to generate the solution for these problems. it needed to take seriously and look down into a solution. Even the changes take time but at least the progress of the program can be seeing in the company. This time is the top management can see the performance of their employees and at this time also ordinary employees can show their ability to solve kind of matters. These can be seemed in the Japanese company. To changes the company culture it needed team work. Even it is the simple problems.Chapter 3 Problems towards Implementation and sustainable of 5S It is not easy to implement something new in the company and make it became sustain.
This is because when someone else doing liked that others will be followed. so it is one of the efforts to use in term of generating the successfulness of 5S. give reward and incentive for the employees who show outstanding performance towards 5S implementation. Sometimes they are not responsible for their work station and just leave it anything after been used and expected someone else will be covered. By sustaining and maintain the 5S systems. It needed to balance between implementation and sustainable of 5S systems. This is because they are chance for a certain period and would back again to their old habits. That why it needed to be sustaining to ensure it flow smoothly as planned. That why disciplinary is important to teach them to be responsible and care about their job scope and work station. It is not worth it if taking care only for an implementation only but not focusing towards the sustainable of 5S systems. To avoid this matter become worsen drastic measure need to be taken and ensure it not be repeatedly happen in the future. This will motivate the employees to enhance their performance. When it move smoothly. When we are implementing something we need to make sure it is flow like as we are planned and not stuck at a certain stage. If any measures not been taken it would be being habits and in the future it becomes the company culture. the employees also will take seriously about this implementation and give fully cooperation to make it the successfulness of the programme. This is because anything to setup things needed money.
. In this case MACES needed to allocate sum of money into this program to ensure sustaining this implementation. This will makes the development of 5S systems become not systematic. MACES can create employee of the month who is perform well to support the implementation and giving up he reward and incentive. For example it can be used to decorate the office to looks more nicely. They think the company is not really care about this thing.Another thing is the sense of ownerships of employees towards their work station. design a shirt for 5S awareness for all employees etc. it is easy to monitor it. Besides that the investment of money towards 5S also playing a role to support the implementation and sustainable of a 5S systems.
• Safety – Safer working environment.
. The first need to be considered is by making sure the employees are enjoying the implementation of 5S. • Savings – Decreased costs. this will makes the 5S system can be sustainable and contributing to the successfulness of the implementation. • Standardization – Standardized operating procedures. If they are enjoying. • Satisfaction – Satisfied employees and customers. they are motivate to do something in return to the companies especially the implementation of 5S system. So the management needs to do something to chance the working culture to ensure all employees are following the order and instruction given.Chapter 4 Recommendation Towards 5S Implementation and Sustainable Chu (2009) presents a 5S framework to summarize these benefits: • Sales – Increased sales (market share). Grout (2009) emphasizes that a 5S program supports a visual work environment that is: • Self-explaining • Self-ordering • Self-regulating • Self-improving The implementation can’t be realized without fully cooperation and commitment been giving up by employees.
This will create two ways communication between the management and employees. All of the employees need to participate and contributing something towards its successfulness. Another ways is by put up the suggestion box. At the shirt the company can put up the motto need to be achieved every year. The commitments among the employees are the main issues that contributing to the 5S success. suggestion.
. anyone are freely to comment or says something to improve the implementation of 5S anytime without anyone know. The company need to encourage and the enforcement if the employees are not showing their interested toward 5S. the company also should do aggressive promotional activities to ensure the implementation of 5S is not only for a certain period only. This can be done through plan properly the daily. monthly and yearly events of these 5S programs and advertise it. The company also can put up the posters or anything else to remind them about the 5S system. Besides that. In the 5S implementation it is impossible to achieve is it is involve one man show. opinion etc. The company can design special shirt for this day and need to change every year. The company creates one day for 5S day to show the commitment of company into 5S system and to keep the system is running in the company. If the company organizes any event involving 5S make sure all employees are participating either from top level to the ordinary staff. They can channel up anything that in their mind either direct or indirect channel. In this day all employees need to wear 5S shirt. weekly. This will make them aware about the activities and they know 5S are the company system that they need to following up.Basic rules are making sure the employees are interested with the 5S system. Give them opportunity to participate towards this implementation by allowing them to voice up their opinion. Educate them and lets them aware that the companies are serious about this thing. The management also needs to open minded to hear all of the comments.
as it pits groups against one another and destroys a team approach to enterprise-wide commitment to excellence. these must be on the basis that everyone celebrates and participates in success together because all parts of the organization have achieved a shared target. Use the “Red Tagging” tool to identify unneeded items during the sort phase of 5S. If rewards or incentives will be given. Cooperation and commitment are important in the 5S system and anyone should know their roles in the 5S system and done their responsibilities to ensuring the sustainable of 5S in the company. Below are activities or progress can be implied at the company towards the 5S systems in order to achieve the successfulness and sustaining it: Sort – sort out what you don’t need (when in doubt. to ensure all employees are participate in the 5S system is through giving them rewards and incentives.This is because if everyone in the company is participating this will motivate each others to realize the 5S system and ensure the sustainable of 5S in the future. Listed on the red tagged items: • • • • • Item classification Item ID and quantity Reason for red tagging Work section Date
. Setting up individual area rewards is dangerous. In the nut shell. They will be appreciable toward their hard work to realize the 5S implementation in the company. throw it out).
The team makes the final decision.Take the red tag items to a removal location. and so on to reduce the waste of motion. Anyone can plead the case for the item to stay. Set in order – organize what’s left so as to minimize wasted motion (a place for everything. Keep in mind how to place machines. well-ordered workplace. Shine (and Inspect) – Nothing raises a team’s spirit like a clean. and equipment. storage shelves. This involves: • • • • • • • What to clean How to clean Who will do the cleaning How clean is clean Develop checklists of what should be cleaned Cleaning responsibilities and schedules should be prominently posted 5S stations should be set up and stocked with cleaning supplies
. and everything in its place).
What equipment should be there 2. Who has taken equipment and when they will return it. Effective standards make the out-of-standard condition obvious. contests. simple. 5S must belong to each team member through: • • Promotion and Communication (report boards. Sustain – ensure that 5S develops deep roots through involvement. 5S core group) Training
Source: Oakland University (Pawley Learning Institute)
. and visual. Example: an office equipment board tells us 1. • • • Remember that the best standards are clear.Standardize – maintain the good condition by applying standards for sort to shine. What equipment currently are there 3.
and improved. This makes it easy to find things because everything has a place and everything is always in that place. If the employees well understand the benefits of a 5S they will be more disciplined and know their roles and responsibilities in order to make sure the sustainable of 5S systems in the company. it becomes the new standard. • Improved – People then understand that 5S is about improving the standards for how work is done. When a better way is found. but this is only the beginning of understanding a 5S effort. visible. Cleaning a work area is a good practice.
. • Standard – People soon learn that 5S is about making this improved work process a standard work process and keeping it standard. standard.These are the five stages of the understanding benefits of 5S and it can be as a guideline for a company to implement of 5S systems in the company. 5S challenges people to always be looking for better ways to organize their work to make the work simple. A visual work area provides cues that help workers and supervisors immediately know the current status of the system and quickly identify if anything needs immediate attention. error-proof. • Visible – People understand that 5S is about making work more visible so that workers can focus on their work and so that anything out of place “screams” for immediate attention. However. Below are the five stages of understanding benefits of 5S program that the employees should be know. These five stages are described as follows: Five stages of understanding the benefits of a 5S program • Clean – People often assume that 5S is just cleaning up the work area. clean and standard is just the beginning of understanding 5S. and wasteless. 5S is more than just clean. However. It also would be easy to instruct any continues improvement program towards 5S in the future.
instruments. through this practical steps company can enhance and advance the implementation of 5S and keep update the progress of 5S program in the company.
This is the suggested practical steps for implementing of a 5S program in the company.• Disciplined – People finally understand that 5S is about developing and practicing a highly disciplined mindset for how work is done. old parts.
. In this stage. Implementing the sort step • Take photos before you begin – Before implementing a 5S program. personal items. including scrap. It also would be as a source to strengthen the already make 5S program in the company. and duplicate tools. These also show the commitment of a company to realize the implementation of 5S in the company. • Identify low value items – Identify all excess items from work areas. A good rule of thumb is to identify and eliminate any items that have not been used in the last three months. and equipment. Recycle or throw away all items that clearly have no value. it is a good idea to take photographs to document and encourage improvement. unneeded supplies. duplicate supplies. workers wholeheartedly embrace the concept and find that this discipline carries over into everything they do.
error-proof. and the category.
. • Evaluate and dispose of red tag items – If items in the red tag area are not claimed or sold after a month. visible. and standard. Common red tag categories for a manufacturer include: • Raw materials • Work-in-process • Finished goods • Tools or fixtures • Equipment • Maintenance or MRO supplies • Office equipment or supplies • Other • Move red tag items to the red tag area – Move red tag items into the red tag area to be evaluated.• Create red tags – Create a red tag for all items of possible value that are no longer needed. discard or recycle them. wasteless. number of items. The red tag usually includes the current date. Some firms use a green tag to indicate that the item should definitely be kept and a yellow tag to indicate that no decision has yet been made. Implementing the set in order step Remember that the key idea here is “a place for everything and everything in its place” and that the goal is to make the work area simple.
and measuring devices.• Organize the physical layout – Start by organizing the physical layout of the work area to improve visibility and workflow and reduce wasted steps and motion. Design storage areas with a wide entrance and shallow depth. and holders – Use carts. • Make proper use of carts. This might include removing unnecessary doors. 5S generally requires that almost nothing touch the floor other than table legs and equipment supports. Use racks and shelves when possible. Use colors to quickly identify items. For example. containers.
. containers. Use seethrough/transparent covers and doors for visibility. Use shadow boards for tools. movement. Paint the floor to indicate where larger pieces of equipment should be stored and where people are to walk and not walk. supplies. Use small bins to organize small items. and reference materials as close as possible to the point of use and make sure that the items used most often are closest to the point of use. and store tools. • Locate items to reduce walking and motion – Move tools. move. • Make the area standard and visible – Clearly label items. shelves. and other areas to improve visibility. jigs. Store similar items together and different items in separate rows. • Make the area safe – Identify safety issues and mitigate all significant risks. walls. or travel. and other barriers that inhibit visibility. and tool holders to organize. removing doors from cupboards is often a good way to improve visibility and save time. materials. Do not stack items together. Lay out the storage area along the wall to save space.
wash. • Implement across all units – This new standard should be implemented across all units.
. This standard will be the basis for 5S audits. and shine everything around the work area. clean. Implementing the standardize step • Create the standard for the work area – This includes listing the items and the number of items allowed in storage. • Be quick to revise the standards – It is important to not only have a standard. This is because it is often better to clean and shine before putting things back in the work area. • Clean – Sweep.Implementing the shine step It is often better to do the shine step before the set in order step. • Create a standard cleaning procedure – The standard cleaning procedure should include a cleaning checklist and should be posted close to the work area. It should also define how often the area will be cleaned. including the floor. • Arrange cleaning materials – Practicing 5S means that all employees should have their cleaning materials in a standard place close to the work area. but to update it as often as needed.
ask “why” five times to address the system of causes for the problem. Many organizations make it “standard work” for supervisors to “scorecard” work areas at least once per week. Even last month’s manual should be out of date. but I know that violates the 5S concept. the former Vice President of Production at Toyota Motor Corporation. • Learn from mistakes – When an area is found to be out of compliance with the 5S standard. This involves developing the habit of always putting things back in the proper place. Hill
. “Something is wrong if workers do not look each day. and a simple process for this person to change the standard as needed.” One healthcare worker reported that “Our exam room was 5S’ed and they removed things that we need to keep in the room. people might have a bad habit of putting tools and papers on a table or desk when they should instead immediately put them away. I wish I knew who to talk to about this. Bodek (2009) quotes Ohno. and removing items of little or no value. • Schedule regular audits – These audits should be done to provide accountability. find things that are tedious or boring. Begin to develop a disciplined culture of keeping the work area up to 5S standards at all times. one person who visibly “owns” the standard. and then rewrite the procedures. For example. • Empower people to change to a new standard as needed – With respect to quickly changing standards. See the appendix for a suggested simple 5S scorecard. making sure that everything is always in the right place.” This quote highlights the need to have involvement of the people in the “gemba”6 to create the standard. Source: Professor Arthur v. I’d like to bring the items back in. • Develop the culture – Ensure that 5S goes beyond just keeping the work area clean.Implementing the sustain step • Take and post “after” photos – One simple way to encourage participation and improvement is to take photographs to document the improvement.
Chapter 5 Conclusion towards 5S Implementation and Sustainable MACES had gone through the implementation and sustainable of 5S and everything is well documented and planned an activities and programme to support the implementation and sustainable of 5S. The outcome of an implementation of 5S can be seeing at MACES and lots of thing had been changes into more productive and effective. Without cooperation and team work this implementation can stay for a certain period and it will be forgotten if any measures not been taken to improve it. awareness etc in order to sustaining the implementation of 5S at MACES. Thus it can enhance awareness and the employees are known their responsibilities to make sure the successfulness of 5S programme. MACES need to establish clear methods and standards to make sure their employees are known and clear about the mission and vision of MACES towards 5S. Besides that 5S also not a one man show work and it needed cooperation each employee to support the changes of work culture to be better in the future. This will enhance the company performance and the employees will know about the latest trend or issues into 5S systems. From this the rules and standard operation procedure are always been up to date due to the current situation. So. cooperation. It can be done in the form of monthly 5S newsletter announcement to let the employees aware about it. To implement of 5S is not a one day jobs. it need to consume lots of time to planned. the latest implementation into 5S is keep update and knowing what is the latest scenario on the 5S systems. The 5S is need to be improve every time as a benchmark for continues improvement (Kaizen).
. Only for a certain part that needed to be improve in term of team work. What MACES really needed to strengthen the implementation and sustainable by adding newest approach to encourage the involvement of employees towards this implementation and sustainable this programme in the future. implement and sustain it.