Professional Documents
Culture Documents
PGP 5 S
PGP 5 S
on
5S
( Work Place Improvement )
Contents :-
1. What is 5 S ?
2. Implementation methodology.
3. Sustenance ( Holding Gains).
4. Review and measure.
What is 5S ?
5S?
L
X D
Housekeeping
5S
? Housekeeping
OR
L
Improvement Process K
5S
J
Improvement Process
5S
=
Work Place
Improvement
1 S,
2 S,
5 3 S,
4 S,
5 S.
1 Sorting Out. 5 S
2 Systematic Arrangement.
3 Shine Everything.
4 Standardization.
5 Self Discipline.
5 ‘S’ & It’s Benefits
Topic Understanding Actions to be taken Benefits
1 ‘S’ Sorting Out • Segregate Wanted & Un-Wanted things . Space Saving & Improvement
• Remove Un-Wanted ones. in Work Efficiency .
• Decide on frequency of sorting.
3 ‘S’ Shine Everything •Dust Free Equipment / Work Place. •Healthy Work environment
(Cleaning) • Make it easy to Clean. •Abnormalities are Visible
• Make it easy to Inspect Abnormalities. & Corrected.
4 ‘S’ Standardization •Standard Procedure for all activities. Achieving Higher Productivity
•Review of Procedures and Work and Better Quality.
Instructions at a Fixed Interval.
5 ‘S’ Self Discipline • Forming the Habit / Culture. •Habit of doing it Right
• Regular Training & Update. First Time and Every Time .
• Follow the decided things. Total Employees
Involvement.
1Sorting out :
RED
TAG AREA
Team members
of operators
Make zones by allocating a reasonable area
to each leader
1Sorting out :
Methodology to Implement 1S: ( Contd.…)
•Fix a date and time for Red Tag Campaign & carry out the
audit across all Zones.
•Search & Identify unwanted things and tie them with a RED
TAG.
•Other than product scrap, Red Tagged items should be moved
to respective RED TAG AREA.
•All those items which are finally identified unwanted ones
should be reviewed by the review committee and decision for
disposing off should be taken within a fixed time( Maximum
Time Limit is 15 days).
RED TAG CAMPAIGN
questions: Action :-
FILING RACK IN
DIS-ARRAY
Before
Habit After
of accumulating unwanted things
Rack Removal
DISPATCH DEPARTMENT
BEFORE AFTER
RACKS TO BE
REMOVED
6x8 feet space released
Before
Before After
Worst Example of “1 S”
Worst Example of ‘1S’
2S
Systematic
Arrangement
2S (Systematic Arrangement)
Objective
•Place for Every Useful Thing & Every Useful Thing is
on it’s place .
•Arranging them in a Systematic manner.
Before
Pre-Fixed After
Locations
2S
Pre-Fixed
Locations
‘2 S’
Pre fixed
locations
2S
Search
Time
Elimination
Fan &
Electrical
Switches
Identified
2S Shadow Boards
Shadow board means if you take tool / gauge
anything from that board , shadow of that
tool/gauge should remain on the board (empty
place )
… refer next slide
2S Shadow Boards
Before After
Wrong place for wrong Tool Correct Tool on correct place
2S Example of ‘2S ’
Before After
Wrong place for parts
2S ‘2S’ in Office
• Can you see at a glance
whether files are out of
place ? Elimination of
• Can you detect disorder search time
from a distance ?
Before After
2S Example of ‘2S’ at office area
2S See through , see without touching / opening
TOOL STORAGE
AT CORRECT
LOCATION
2S
COCONUT TO CAR PARKING
BEFORE AFTER
BEFORE AFTER
2S
COCONUT TO CAR PARKING
BEFORE AFTER
2S
COCONUT TO CAR PARKING
BEFORE AFTER
Direction Dispensary
ATTENTION
240/440 V
DANGER
Shine
Everything
3 S (Shine everything )
means……
Mops
• Used for wiping Floors,Table Top, Shelves .
Factory Surroundings
3 S (Shine everything )
Front area and Scrap yard are comparable
31.03.02
Before After
3S
Before
Wet to Dry….
Nothing is on the floor
After
3 S (Shine everything )
Example of Wet to Dry
BEFORE AFTER
3 S ( Shine everything )
MAXIMUM UTILISATION OF NATURAL LIGHT
Transparent
Sheets
Dark to bright
4S
Standardization
4 S (Standardization)
Objective
• To set standard practices for carrying out
routine / repetitive work in the best known way.
Self
Discipline
5 S (Self Discipline)
Follow the Standards
…….Achieve through
1 People are aware for " 5S " requirement and their doing their role ( ask 2-3 people ) 20
2 Availability of operating Standards ( Operation sheet , work instructions ) and are effective 20
3 Activities are done as per schedule ( Audit , Action on NC products etc. ) 20
4 Appropriate legible Visual Control System In Practice ( area names , displays ) 20
TOTAL FOR 5S 80
5S SCORE = ( TOTAL s core X 100 /80)
Best = 100 % marks, Good= 70 % marks, Average= 50 % marks, Below Av.= 30 % Marks, Poor= 10 % Marks, Not done at all= 0 % Marks.
Radar Chart
1S •Section
SORT OUT
•Date
20
15
10
5S 2S
SELF 5 SYSTEMATIC
DISCIPLINE ARRANGEMENT
0
4S 3S
STANDARDIZATION SHINE
EVERYTHING
•100
Graph
•80
•60
•40
•20
Marks %
Month
5S is not one time activity, it’s a
Continuous IMPROVEMENT
PROCESS .
No TQM,TPM,TPS..LEAN is
possible without 5 S
5S……..a way of life.
Thank you