Republic of the Philippines

Technological University of the Philippines

COLLEGE OF INDUSTRIAL TECHNOLOGY
Ayala Blvd., Ermita Manila, 1000, Philippines
Tel No. +632-301-3001 local 604 | Fax No. +632-521-4063
Email: registrar@tup.edu.ph | Website: www.tup.edu.ph

ASSIGNMENT #1

THE 5S METHODOLOGY

WHAT IS THE 5S METHODOLOGY?

• The 5S methodology is often summarized by the philosophy of “a place

for everything and everything in its place.”
• You may have heard of “KonMari,” a home organization system
propagated by Marie Kondo. The KonMari method transforms cluttered
homes into tidy and simplified living spaces. The 5S principles are
similar to KonMari. However, saying that 5S is just about tidying is like
saying yoga is just about stretching. In other words, there is much more
depth.
5S ORIGINATED AS 5 JAPANESE WORDS:

1. Seiri/Sort: Eliminate that which is not needed.

2. Seiton/Straighten: Organize what remains after sorting.
3. Seisou/Shine: Clean and inspect the work area.
4. Seiketsu/Standardize: Write standards for 5S
5. Shitsuke/Sustain: Consistently apply the 5S standards.

At their core, 5S activities build the discipline needed for substantial and
continuous improvement by creating (and sustaining) efficient and effective
work areas.

SORT

• The Sort step separates items in your workspace that you know you need
from those that you do not need or may not need by moving the latter to
a “red tag” holding area.

WHY DO YOU NEED SORT?

• Sort enables you to have a more productive workspace by removing

unneeded clutter (and eliminating distractions). It also is a first step
towards opening up space that can be used for other things.

HOW DO YOU IMPLEMENT SORT?

Separate necessary items (e.g., tools, parts, and materials) from unnecessary
items. We recommend sorting items into four categories:
 1. Items needed in this work area
2. Items needed in another work area
3. Items you may need
4. Items you do not need.

SET IN ORDER

• The Straighten step thoroughly organizes the items that remain after
sorting, such that frequently used items are easy to access and every
item has a clear and easy-to-find home.

WHY DO YOU NEED TO STRAIGHTEN?

• Straighten enables every item to have a specific home where it can be

easily found and to which it can be easily returned. It reduces the waste
from excess motion as items are placed In more ergonomic locations. It is
also the second step towards opening up space that can be used for
other things.

HOW DO YOU IMPLEMENT STRAIGHTEN?

After you’ve sorted items, it’s time to decide how you want to organize them. We
recommend the following methodology:

• Provide easy access to frequently used items

• Group like items.
• Visualize item homes.
• Use containers
• Unleash the labeler
• Be agile
WHAT ARE SOME EXAMPLES OF STRAIGHTEN?

• Give every item a distinct “home.”

• Use color as a way of organizing and creating meaning.
• Separate everyday tools from special-case tools.
• Dedicate a surface or area entirely to shadow boxes and tool storage.
• Dedicate another surface or area entirely to working.

SHINE

• The Shine step elevates the work area by thoroughly cleaning and
inspecting tools, equipment, and other items. It also can include routine
maintenance on equipment, which is one of the ways it flows directly into
TPM.

WHY DO YOU NEED TO SHINE?

• Shine creates a work environment that engages and empowers operators

by giving them more responsibility and agency over their work area. It
also helps them to identify problems before they interfere with
production. For example, in a clean work environment, it is much easier
to spot emerging issues such as fluid leaks, material spills, metal
shavings from unexpected wear, hairline cracks in mechanisms, etc.

HOW DO YOU IMPLEMENT SHINE?

After you’ve straightened items, it’s time to elevate the work area by cleaning,
inspecting, and in some cases performing routine maintenance. We recommend
the following:

• Grab the metaphorical spray bottle.

• Find the source.
• Inspect
WHAT ARE SOME EXAMPLES OF SHINE?

• Wipe down equipment.

• Examine the wear of your tools.
• Disassemble larger objects to inspect the state of their parts.
• Investigate a recurring unclean spot or mess.
• Make sure to follow proper cleaning procedures to prevent damage
to equipment.

STANDARDIZE

• The Standardize step is a bridge between the first three steps (Sort,
Straighten, Shine) and the last step (Sustain). In this step, your goal is to
capture best practices for 5S as standardized work for your team.

WHY DO YOU NEED TO STANDARDIZE?

• Standardize makes 5S repeatable. It transforms 5S from a one-off project

to a reproducible set of activities.

HOW DO YOU IMPLEMENT STANDARDIZE?

It’s time to make sure all your hard work continues to pay dividends into the
future. Set expectations for the future with a documented 5S process. To do so,
we recommend that you:

• Document in pairs.
• Capture the essence.
• Prefer checklists.
• Organize to simplify.
WHAT ARE SOME EXAMPLES OF STANDARDIZE?

• Write down your 5S practices.

• Create “implementation” checklists and “audit” checklists.
• Create “kits” that contain the materials needed to perform a
specific task.
• Use photos and other simple visuals as part of your training
materials.
• Build a schedule for tasks.

SUSTAIN

• The Sustain step assures that 5S is applied on an ongoing basis. It

transforms your standardized 5S processes into regularly completed
tasks.

WHY DO YOU NEED TO SUSTAIN?

• Iterative 5S processes lock in your gains and ensure further and

continued progress.

HOW DO YOU IMPLEMENT SUSTAIN?

Once you’ve standardized, it’s time to continually act upon those standards.
We recommend you:

• Create a schedule.
• Teach through demonstration.
• Supervise to solo
• Adapt as necessary.
WHAT ARE SOME EXAMPLES OF SUSTAIN?

• Hold a demonstration meeting to explain complex or multi-step

processes.
• Perform periodic check-ins after initial training.
• Teach employees to run 5S audits.
• Respond to mistakes with additional training.
• Encourage supervisors and operators to communicate openly and
constructively to find ways to improve your 5S implementation.
• Set quarterly audit reminders for reviewing the red tag holding area.

WHAT ARE THE BENEFITS OF A 5S PROGRAM?

• Creating space within your facility by removing unnecessary tools

and equipment
• Reducing waste from unnecessary motion by organizing the
workspace
• Reducing down time and improving quality by consistently
maintaining equipment
• Engaging operators by granting them more responsibility for their
work environment
• Creating a safer work environment by ensuring it is clean and well-
maintained
 HISTORY OF AUTOMOTIVE INDUSTRY

The automobile was first invented and perfected in Germany and

France in the late 1800s, though Americans quickly came to
dominate the automotive industry in the first half of the twentieth
century.

Henry Ford innovated mass-

production techniques that
became standard, and Ford,
General Motors and Chrysler
emerged as the “Big Three” auto
companies by the 1920s.
Manufacturers funneled their
resources to the military during
World War II, and afterward
automobile production in Europe and Japan soared to meet growing
demand. Once vital to the expansion of American urban centers,
the industry had become a shared global enterprise with the rise of
Japan as the leading automaker by 1980.

Although the automobile was to have its greatest social and

economic impact in the United States, it was initially perfected in
Germany and France toward the end of the nineteenth century by
such men as Gottlieb Daimler, Karl Benz, Nicolaus Otto and Emile
Levassor.

Gottlieb Daimler, was a German

engineer, industrial designer and
industrialist born in Schorndorf
(Kingdom of Württemberg, a federal
state of the German Confederation),
in what is now Germany. He was a
pioneer of internal-combustion
engines and automobile
development. He invented the high-speed liquid petroleum-fueled
engine.Daimler and his lifelong business partner Wilhelm Maybach
were two inventors whose goal was to create small, high-speed
engines to be mounted in any kind of locomotion device. In 1883
they designed a horizontal cylinder layout compressed charge liquid
petroleum engine that fulfilled Daimler’s desire for a high speed
engine which could be throttled, making it useful in transportation
applications. This engine was called Daimler’s Dream.

In 1885 they designed a vertical

cylinder version of this engine which
they subsequently fitted to a two-
wheeler, the first internal
combustion motorcycle which was
named the Petroleum Reitwagen
(Riding Car) and, in the next year, to
a coach, and a boat. Daimler called
this engine the grandfather clock
engine (Standuhr) because of its
resemblance to a large pendulum
clock.

Carl Friedrich Benz, was a German

engine designer and automotive
engineer. His Benz Patent Motorcar
from 1885 is considered the first
practical modern automobile and
first car put into series production.
He received a patent for the
motorcar in 1886.His company Benz
& Cie., based in Mannheim, was the
world’s first automobile plant and
largest of its day. In 1926, it merged
with Daimler Motoren Gesellschaft
to form Daimler-Benz, which
produces the Mercedes-Benz among
other brands.Benz is widely regarded as “the father of the car”, as
well as the “father of the automobile industry”.
 Nicolaus Otto, was a German
engineer who successfully
developed the compressed charge
internal combustion engine which
ran on petroleum gas and led to the
modern internal combustion
engine. The Association of German
Engineers (VDI) created DIN
standard 1940 which says "Otto
Engine: internal combustion engine
in which the ignition of the
compressed fuel-air mixture is initiated by a timed spark", which
has been applied to all engines of this type since.

Émile Constant Levassor, was a

French engineer and a pioneer of the
automobile industry and car racing in
France.
 When Were Cars Invented?

The 1901 Mercedes, designed by Wilhelm Maybach for Daimler

Motoren Gesellschaft, deserves credit for being the first modern
motorcar in all essentials.Its thirty-five-horsepower engine weighed
only fourteen pounds per horsepower, and it achieved a top speed
of fifty-three miles per hour. By 1909, with the most integrated
automobile factory in Europe, Daimler employed some seventeen
hundred workers to produce fewer than a thousand cars per year.

Nothing illustrates the superiority of European design better than

the sharp contrast between this first Mercedes model and Ransom
E. Olds‘ 1901-1906 one-cylinder, three-horsepower, tiller-steered,
curved-dash Oldsmobile, which was merely a motorized horse
buggy. But the Olds sold for only $650, putting it within reach of
middle-class Americans, and the 1904 Olds output of 5,508 units
surpassed any car production previously accomplished.The central
problem of automotive technology over the first decade of the
twentieth century would be reconciling the advanced design of the
1901 Mercedes with the moderate price and low operating expenses
of the Olds. This would be overwhelmingly an American
achievement.
 Bicycle mechanics J. Frank and
Charles Duryea of Springfield,
Massachusetts, had designed the
first successful American gasoline
automobile in 1893, then won the
first American car race in 1895,
and went on to make the first sale
of an American-made gasoline car
the next year.Thirty American
manufacturers produced 2,500
motor vehicles in 1899, and some
485 companies entered the business in the next decade.

In 1908 Henry Ford introduced the

Model T and William Durant founded
General Motors.The new firms operated
in an unprecedented seller’s market for
an expensive consumer goods item. With
its vast land area and a hinterland of
scattered and isolated settlements, the
United States had a far greater need for
automotive transportation than the
nations of Europe. Great demand was ensured, too, by a
significantly higher per capita income and more equitable income
distribution than European countries.Given the American
manufacturing tradition, it was also inevitable that cars would be
produced in larger volume at lower prices than in Europe. The
absence of tariff barriers between the states encouraged sales over a
wide geographic area. Cheap raw materials and a chronic shortage
of skilled labor early encouraged the mechanization of Industrial
processes in the United States.
 HISTORY OF DIESEL ENGINE

Rudolf Christian Karl Diesel, was a German

inventor and mechanical engineer who is
famous for having invented the diesel engine,
which burns diesel fuel; both are named after
him. In 1885, Diesel set up his first shop in
Paris to begin development of a compression
ignition engine. The process would last 13
years. In the 1890s, he received a number of
patents for his Invention of an efficient, slow
burning, compression ignition, internal combustion engine. From
1893 to 1897, Diesel further developed his ideas at
Maschinenfabrik-Augsburg AG (later Maschinenfabrik Augsburg
Nürnberg or MAN). In addition to MAN, Sulzer Brothers of
Switzerland took an early interest in Diesel’s work, buying certain
rights to Diesel’s invention in 1893.At MAN in Augsburg, prototype
testing began with a 150 mm bore/400 mm stroke design on
August 10, 1893. While the first engine test was unsuccessful, a
series of improvements and subsequent tests led to a successful
test on February 17, 1897 when Diesel demonstrated an efficiency
of 26.2% with the engine, Figure 2, under load a significant
achievement given that the then popular steam engine had an
efficiency of about 10%. The first Sulzer built diesel engine was
started in June 1898

Development of Diesel’s invention

needed more time and work to
become a commercial success. Many
engineers and developers joined in the
work to improve the market viability
of the idea created by Rudolf Diesel.
He, on the other hand, became
somewhat threatened by this process
and was not always able to find
common language with other engine
designers developing his invention.
Diesel’s attempts of market promotion
of the not-yet-ready engine eventually
led into a nervous breakdown. In 1913, deeply troubled by
criticisms of his role in developing the engine, he mysteriously
vanished from a ship on a voyage to England, presumably
committing suicide . After Diesel’s patents started to expire, a
number of other companies took his invention and developed it
further.