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5S

THE SECRET TO

JAPANESE SUCCESS

3 June 2010

5S The Secret to Japanese Success

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Respect for Workers is Key to Success of Any Program

IDEA BEHIND 5S
• IN ORDER TO ACHIEVE HIGH LEVELS OF QUALITY, SAFETY,AND PRODUCTIVITY, WORKERS MUST HAVE A CONDUCIVE WORKING ENVIRONMENT

3 June 2010

5S The Secret to Japanese Success

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Respect for Workers is Key to Success of Any Program

WHAT IS 5S?
• Developed by the Japanese • Housekeeping System • Helps Create a Better Working Environment and a Consistently High Quality Process • It is the starting point of QC Tools
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WHAT IS 5S?
It is a structured approach and easy-to-understand methodology for systematically creating and maintaining an… • Organized • Clean … … work environment • Safe • And high-performance It creates a foundation for continuous improvement
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and together we will implement it and make it work. not harder.Who Implements 5S ? • Who has a better idea to make our jobs easier than us? We together will implement 5S. 5S The Secret to Japanese Success 5 • • • 3 June 2010 . We want to work smarter. We will teach the 5S process.

THE 5S PRINCIPLES • SEIRI – 整理 .Orderliness/SET IN ORDER • SEISO – 清掃 .STANDARDIZE • SHITSUKE– 躾 3 June 2010 Discipline/SUSTAIN 6 5S The Secret to Japanese Success .The Cleaning/SHINE • SEIKETSU– 清潔.Organisation/SORT • SEITON –整頓 .

move it out!” 2. Shine—Clean everything. Use visual sweeps to ensure everything is where it should be and that junk is not accumulating.Elements of a 5S Program 1. (Red Tag Exercise) “When in doubt. inside and out. 4. Sort— Separate needed items from unneeded items and move them out to an established area for disposition within a predetermined time. Standardize—Create the rules for maintaining and controlling the first 3 S’s. 3 June 2010 5S The Secret to Japanese Success 7 . Sustain—Ensure adherence to the 5S standards through communication. Set in Order— Arrange the remaining items for easy access and Visualization . Use visual controls. 3. 5. self-discipline and rewards.

st 1 S: SORT Differentiate between necessary and unnecessary items and remove everything that is not required • GO THROUGH EVERY ITEM IN THE WORK PLACE • Decide what you need and in what quantity • Red tag the items not needed and place them in already designated red tag area • Re-evaluate at the of the exercise • Remove items which are broken. unusable or only occasionally used 3 June 2010 5S The Secret to Japanese Success 8 .

printer cartridges. • Stacks of Paper. fittings. tool boxes. file boxes • Computer documents • Books. cabinets. 3 June 2010 5S The Secret to Japanese Success 9 . carts. magazines. pallets etc. files. drawings. and newspapers. old posters. folders. tools. old printer paper.RED TAG TECHNIQUES • Look for: • Equipment.

BEWARE OF EXCUSES • We may need it • When we need it. MOVE IT OUT 3 June 2010 5S The Secret to Japanese Success 10 . we may not be able to get it • There is cost to throw it away • It took a longtime to prepare it • It cost a lot to prepare it • WHEN IN DOUBT.

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STRATIFICATION MANAGEMENT: SORTING & EVALUATION CRITERIA NOT USED OR NOT LIKELY TO BE USED DISPOSE NOT USED IN PAST YEAR USED ONCE IN PAST 6/12 M STORE AT A DISTANCE LOW USE SORTING CRITERIA AVERAGE USE USED ONCE IN PAST 2-6 M USED MORE THAN ONCE/M STORE IN A CENTRAL PLACE USED ONCE A WEEK HIGH USE USED EVERY DAY USED EVERY HOUR STORE NEAR WORKSITE 3 June 2010 5S The Secret to Japanese Success 12 .

3 June 2010 5S The Secret to Japanese Success 13 .

RED TAGGING IN ACTION 3 June 2010 5S The Secret to Japanese Success 14 .

RESULTS OF PROPER SORT Non functional equipment Multiple sharps containers After implementing red tag sort. usable bench space was created. ? 3 June 2010 5S The Secret to Japanese Success 15 .

If you stop now. We removed lot of stuff and now have all of this extra space. We don’t need to go forward with the next four steps.Potential Failure Point #1 The area looks good now. freed up space will be disappear again and unnecessary items will creep back into the area 3 June 2010 5S The Secret to Japanese Success 16 .

.. “A place for everything. • Arrange and identify everything for frequency of use and ease of use. consumable. in the workplace must have a home. tool.Seiton .Orderliness Definition • Every piece of equipment.S: Set in Order. and everything in its place” 3 June 2010 5S The Secret to Japanese Success 17 nd 2 .. etc. .

Set In Order Steps to “Set In Order” • Identify the items left after SORT • Determine how much/how many should be there • Make an outline for it if possible All items should be easy to find.nd 2 S . retrieve. 3 June 2010 5S The Secret to Japanese Success 18 . and put away.

then smaller items • Define item placement by frequency of use • Group items that are used together (ex. pipette and tips) • Items should be easy to find.Tips for Setting in Order • Start by identifying home locations for larger items first. and put back • Make good arrangement a habit 3 June 2010 5S The Secret to Japanese Success 19 . use.nd 2 S .

Set In Order Frequency of Use Analysis Where should this item be located? 50 How about this one? Frequency of gets and putTimes/Day 40 30 20 10 aways 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Distance Carried 3 June 2010 5S The Secret to Japanese Success 20 .2nd S .

Set In Order Before 3 June 2010 5S The Secret to Japanese Success After Items may be outlined so that it is obvious when something is out of place 21 .2S .

Example of 2S “Set in Order 3 June 2010 5S The Secret to Japanese Success 22 .

2S .Set In Order Before 3 June 2010 After 5S The Secret to Japanese Success 23 .

Shine • To maintain the work area for the already sorted and set-in-order items 3 June 2010 5S The Secret to Japanese Success 24 .3S .

cleaned and free of grim.Cleanliness Definition • Making sure that every ……. –piece of equipment • –square foot on the floor. –wall. –working surface • –piece of furniture. • –tool.3S .Shine …Seiso….” 3 June 2010 5S The Secret to Japanese Success 25 .. and kept that way “If it doesn’t get dirty. it doesn’t have to be cleaned. –storage place etc …is swept. dirt and grease.

Examples of 3S “Shine” Manuals need to be returned to proper storage location 3 June 2010 Needed in work area? Tools need to be put in proper location 5S The Secret to Japanese Success 26 .

Examples of 3S “Shine” 3 June 2010 5S The Secret to Japanese Success 27 .

Everyone has a different idea of what “clean” is.Potential Failure Point • The area really looks good now. Standardization gets everyone on the same page 3 June 2010 5S The Secret to Japanese Success 28 . It’s clean and well organized. It will be self sustaining. We are disciplined so we don’t need to standardize.

“Set in Order” and Shining are maintained and protected • It Standardizes the methods required to maintain 1st S. and 3rd S. 3 June 2010 5S The Secret to Japanese Success 29 . practices and activities are defined and executed consistently and at regular time intervals • Ensures that Sorting. 2nd S.4th S – Seiketsu…Standardize Definition • Procedures.

Example of Standardization ACTIVITY MON TUE WED THU FRI COMMENTS/SUGGESTIONS FOR IMPROVEMENTS Check/Empty trash Arrange tools Check incom. repair shelf Clear Clutter/unneeded items File all paper work Wipe down counters .Weekly/ Clean common Refrigerator. Microwave etc Red Tag item Disposition Monthly 3 June 2010 5S The Secret to Japanese Success 30 .

3 June 2010 5S The Secret to Japanese Success 31 . It isn’t a single separate activity. SUSTAIN is different. We SUSTAIN when we have developed habits of always using the first 4 S’s together on a daily basis. We SET IN ORDER work places. With STANDARDIZATION it is easy to identify anything out of place. We SHINE areas.What is SUSTAIN? We SORT areas.

• Maintain improvements and look for opportunities • All associates doing their part to sustain the gains • Develop 5S “Communication Board” • Use audits to monitor adherence to plan • Incorporate 5S into goals and objectives 3 June 2010 5S The Secret to Japanese Success 32 .5th S Sustain • Ensure the first 4Ss are maintained and used properly.

4th S and 5S Audit 3 June 2010 5S The Secret to Japanese Success 33 .

4th S and 5S Audit 5S AUDIT 5S Scores Sort 10 8 6 4 2 0 5 7 Set in Order 9 sustain 6 Standardize 8Shine 3 June 2010 5S The Secret to Japanese Success 34 .

A CLEAN AND TIDY WORKPLACE LEADS TO GREATER WELL BEING AND INCREASED MOTIVATION 4. CREATES WORKPLACE OWNERSHIP 3 June 2010 5S The Secret to Japanese Success 35 .WHAT U HAVE ACHIEVED 1. SAFETY INCREASES 5. WORKSTATIONS BECOME SPACIOUS 3. NEAT & CLEAN WORKPLACE 2.

Bio-Med Before 5S 3 June 2010 5S The Secret to Japanese Success 36 .

Bio-Med After 5S 3 June 2010 5S The Secret to Japanese Success 37 .

BEFORE & AFTER 3 June 2010 5S The Secret to Japanese Success 38 .

BEFORE & AFTER 3 June 2010 5S The Secret to Japanese Success 39 .

BEFORE & AFTER 3 June 2010 5S The Secret to Japanese Success 40 .

Before 3 June 2010 5S The Secret to Japanese Success 41 .

After 3 June 2010 5S The Secret to Japanese Success 42 .

BEFORE & AFTER 3 June 2010 5S The Secret to Japanese Success 43 .

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