Introductory training

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Anyone feel like this now ?

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What is your opinion ?

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What is your opinion ?

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What is your opinion ?

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What is your opinion ?

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What is your opinion ?

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What is your opinion ?

Not pleasant

Uneasy
Irritating

Disturbing
Unsafe

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Searching

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What is 5S?

Boss, Look at my
Master piece ?
Warehouse

!?#@&*
$%!

5S is not to produce aesthetic effects to impress others

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5S - An effective cure to problems

A medicine, easy to take and can cure most problems effectively. It
has no expired date and no side effects

A company is just like human body.

It has to be maintained to its best condition!
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5S Surface out the problems

5S

more than anticipated

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5S in Engineering

To eliminate the wastes that result from uncontrolled processes.

To gain control on equipment, material & inventory placement and position.

Apply Control Techniques to Eliminate Erosion of Improvements.

Standardize Improvements for Maintenance of Critical Process parameters.

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Productivity

Productivity =

Output
----------Input

Productivity can be improved in two ways

For the given output
Increase output

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reduce input
for the given input

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Why productivity ?
To achieve the maximum output from the given input in order to increase
the profitability and to reduce the manufacturing cost

Why low productivity ?

Target
Gap

Wastes

Actual
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Every thing
Takes time
Costs Money

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Value add work vs Non-value add work

All work is either

Value Add
Transforms material or information to meet

the true desires of an external customer

Non-Value Add
Any activity that does not change the state of product / information
to meet the customer requirement

Control
Information
Administration

Other
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Which of these activities add value?

Looking for parts

Searching for info

Building products

Filling out forms

Inspecting

Entering data

Testing

Answering customer questions

Rework

Stocking shelves

Delivering services

Training

Packaging

Selling

Shipping

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Low Hanging fruit

Where do you think you will

find the low hanging fruit
when you begin your
improvement efforts?
By increasing the 5% of value-

add activities?
By reducing the 95% of nonvalue-add activities

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Fundamental principle of process improvement

Anything that does not add

value is waste, and must be
reduced or eliminated

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WASTE :
In lean manufacturing waste is anything that adds to the time and cost of
making a product
but does not add value to the product from the customers point of view.
Value-added activities transform the product into something the customer
wants. In manufacturing this is generally a physical transformation of the
Block
product to make it to conform to customer expectations. Block
Delivery

Panel line

Cutting &
marking

Blast & Prime

Block Assy

Block
painting

errection

outfitting

Figure shows a simplified version of the steps required to make a steel

subassembly..
Stock yard

Buffer

Buffer

Raw material

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Buffer

Buffer

Time
Non value
added

Buffer

Buffer

Finished goods
value added

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Types of wastes
There are eight types of wastes
1. Over production

2. Inventory
3. Conveyance
4. Defect production
5. Process related
6. Operation related
7. Idle time waste
8. Under utilized People
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1. Over production waste

Making what is unnecessary, when it is unnecessary and in an unnecessary

amount

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OVER PRODUCTION
Large batches and Inventory
Planning full utilization of machines and Labors

Producing more goods than market demand

Goal Produce as needed when needed

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2. Inventory waste
It is when anything (materials, parts..) is retained for an length of time. This
includes finished goods as well as in process materials

Inventory is terrible

Inventory is a liability
We want zero inventory
Inventory is to be minimized
Reduce inventory

Inventory is bad, bad, bad

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INVENTORY
High stocks of raw materials, WIP & Finished goods
Additional space requirements

Dis-order

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Cost of Inventory
Cost to borrow money
Insurance
Space

Loss due to damage and

obsolescence
Cost to count it
(over and over)

Cost to move it
(over and over)

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3. Conveyance waste
Created by conveying, transferring, picking up / setting down, piling up and
moving unnecessary items

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TRANSPORTATION
Unnecessary movement
Extra handling

Moving Inventory

Goal There is a place for everything, and everything has its place

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4. Defect production waste

Waste related to costs for inspection of defects in materials, processes,
customer complaints and repairs

Defects

Secondary defects

Primary defects

Processing omissions

Adjustment errors

Processing errors

Miss operation

Missing parts

Work piece setting wrong

Wrong items

Wrong work piece

Incorrect equipment setup

Other errors
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DEFECTS
Large delays for trouble shooting
Costly network

Dissatisfied downstream customers

Goal Doing it Right, the First Time

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5. Processing related waste

Unnecessary processes, operations traditionally accepted as necessary and
process errors

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PROCESSING
Poor machine maintenance
Unnecessary processing steps

Longer lead times

Goal is to Reduce over-processing by doing things right the first

time

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6. Operation related waste

Unnecessary movement, movement that does not add value, movement
that is too slow or too fast

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MOTION
Incorrect Layouts of office, Factory etc.,
Lack of proximity of machines

Off-line resources

Goal is Reduce motion through proper planning, executing, and

maintaining your process

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7. Idle time waste

Waste of which the causes originate in waiting from materials, operations,
conveyance, inspection as well as the idle time attendant to monitoring and
operation procedures
Why doesnt
it start?

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SSrinivasu

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WAITING TIME (DELAYS)

Watching machines work
Long set-up and lead times

Goal is to Be accountable for information needed and

information delivery

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8. Under utilized Manpower waste

Underutilized People Lack of focus or systemic
wastes

Lack of ownership of tasks, unnecessary

assignment
Lack of goal alignment
Lost creative insights

Goal is to Communicate expectation, provide mentoring ,

support, and empowerment

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Our Goal when dealing with WASTE

Goal = Get ever closer to zero

Zero defects

Zero inventory

Zero scrap

Zero handling

Zero rework

Zero paperwork

Zero receiving rejections

Zero mistakes

Zero downtime

Zero absenteeism

Zero waste

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Sort

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Store

Shine

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Standardise

Sustain

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SORT

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SEIRI

Sort out Required item & waste item

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Purpose of having SEIRI

Create valuable and safe working space.
Prevent mistakes: miss-usage, miss-handling, misstransport etc.
Prevent material deformation. Prevent dead lock of fund
and capital.
Create spacious feeling at work place.

Seiri - The approach to raise work efficiency

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Action for SEIRI

Sort out and take out unnecessary

items and discard them

Remember : Bogi

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Action guideline for SEIRI - Steps

Seiri is to perform clearing up (sort) activities with group participation.

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Sort out Wanted items and Unwanted

items.

Dispose off (send for treatment) the

unwanted items

Provide streamlined, safe and proper

storage conditions for wanted items.

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RED Tag - Model

RED TAG

Classification

1. Rawmaterial
2.Work-in-progress
3.Conponent part
4.Finished product

5.Machine / Equipment
6.Mould / Jigs
7.Tools/Fittings
8. Others

Name of the item:

Order number
Quantity/ Value

_____ items , Value / item______ ,

Reason

1.Unnecessary
2.Defective
3.Non Urgent

Section reponsible

_____ Dept. ,

Action

Total :
5.Left over material
6.Unknown
7.Other

Section______ , _______ Group

1.Eliminate
2.Return
3.Move to red tag storage
4.Store seperately
5.Other

Completed

Tag atttached date

Date

Action taken date

Reference no.

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RED Tag

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Action guideline to follow SEIRI

Separate the wanted
& unwanted

Junk & waste

Repairable

No use

Wanted

Repair & use

Discard

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Consequences of not following SEIRI

Keeping unnecessary things needs more space
It becomes difficult to say which is needed and not
Cleaning activity added on the unnecessary parts
Some time it needs maintenance and it adds cost
Creates safety issues in some cases

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P E

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A
O R

R
Z N G
A

M
Z
E B
E T

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SEITON

Arrange in proper order for easy use.

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Purpose of having SEITON

Eliminate unproductive search time.
Create and claim back valuable work space.
Compress stock quantity.
Create systematic, direct visual effect layout (visual
management) at work place.

Seiton - The approach to systematic arrangement

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SEITON

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Action for SEITON

Arrange necessary items in proper

order so that they can be easily
picked up for use

Remember Books arrangement in Library

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Action guideline for SEITON

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Keep the things in order

Every thing in its place

The things to be easily reachable

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SEITON It is simple to remember

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SEITON It is simple to remember

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SEITON

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Some 5S Examples

Before 5S
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After 5S - Cleaned,
organized and drawers
labeled (less time and
frustration hunting)
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5S Examples - Sort, Set in Order

See the difference?

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1. Sort - All unneeded tools, parts and supplies are removed

from the area
2. Set in Order - A place for everything and everything is
in its place
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The Good, Bad and the Ugly

First the Bad and the Ugly - Life Without 5S

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The Good

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Consequences of not following SEITON

Things are seldom available when needed,
More time spent for locating misplaced things
Defective & good items / similar looking items get mixed up
Prone to Loss of production
Excess inventory

Pressure for more space

Items are lost

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CLEANING

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SEISO

Clean your workplace completely

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Purpose of having SEISO

Remove untidiness, prevent dust accumulation.

Expose existing & potential problems.
Promote preventive maintenance.
Prevent accident, secure quality.
Make a clean & pleasant work place.

Study cleaning method

improve cleaning efficiency
eliminate the needs of cleaning.

Seiton - The approach to enhance work quality

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Cleaning means
Checking
Eliminating the causes of defects
Maintaining optimum conditions
Attention to details to achieve the
best conditions

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Action for SEISO

Clean your workplace / surroundings

thoroughly so that there is no dust on
the floors / machines & equipment

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Action guide Guidelines for SEISO

Establish what to clean , cleaning method & responsibility

Real cleaning is something that comes from the heart

Make cleaning everyday a habit

Place

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When

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Consequences of not following SEISO

Dust / dirt will affect the machine performance
Cleaning reveals hidden problems which may get

overlooked otherwise
Dust & dirt will affect performance &
aesthetic quality
Unpleasant work place will result.

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STANDARDISATION

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SEIKETSU

Maintain a high standard of house keeping and workplace

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Purpose of having SEIKETSU

Set up clean and comfortable work place.
Improve, maintain and aim for higher level of
achievement.
Establish higher level of company image.
Bring up product superiority (indirectly).

Seiton - The approach to safety & work enthusiasm

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Action for SEIKETSU

Establish procedures & standards to

maintain 5S and perform regular patrol
to all areas & continually audit the 5S
progress

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Action guidelines for SEIKETSU

Make standards for clean work place
Convert standards to VCS
Facilitate identification of deviations for immediate

corrective actions

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Checklist for 5S Office / Shop floor

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Consequences of not following SEIKETSU

More chance for going back to old condition
Things get measured, will improve

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TRAINING & DISCIPLINE

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SHITSUKE

Train people & follow good house keeping disciplines

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Purpose of having SHITSUKE

To cultivate good habits and sustain the 5S culture.
To maintain a group of well disciplined work force.
Abiding to standards and ruling to secure a clean, safe,
healthy, happy and efficient work place by everyone for
everyone (total work force).

The approach to discipline group works &

continual improvement.
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Action for SHITSUKE

Cultivate spirits of self discipline and

self awareness to maintain, encourage
and continue 5S activities and
sustaining it with timely motivation,
training and sharing of working
results.

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SHITSUKE - Discipline

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Action guideline for SHITSUKE

Train people to follow good house keeping disciplines
automatically
Follow discipline in maintaining 5S and make it a habit

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Summary - 5S concept
SEITON

SEIRI

SEIKETSU

SHITSUKE

SEISO

3
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The implementation of 5S
Step 1 Start with the Leadership Team

Step 2 Build the Infrastructure

Step 3 Launch Communications
Step 4 Train Teams in 5S Techniques
Step 5 Begin 5S Pilots
Step 6 Establish Best Practices
Step 7 Develop a Full Roll-Out Plan
Step 8 Continually Evaluate & Adjust

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5S Visible benefits
Improves on-time delivery
Improves quality / reduced defects
Increases productivity , Reduces lead times
Reduces waste in materials, space and time
Reduces inventory and storage costs

Reduces changeover time , Reduces equipment

downtime
Improves safety
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Action on Ground
Daily monitor and improve the score
Put 5S Score yourself or do it by cross audits
Spend daily first 10 minutes for machine cleaning
Every Saturday spend 1 hour for Seiri & Seiton ( 2s
Activities )

Monthly once conduct red tag campaign to remove

unwanted / scrap materials

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Action on Ground

Can we find areas of improvement

in your Work place ?

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You have to decide

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cell : 9976774372,
9344689828

Thank you

d i f f e r e n t i a t e..

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