Sreedhar Patnaik incharge- process & QA Visakha Steel Allieds
What is work place ? “Work place is where one works” “Where there is an out put” “Where there is creative activity” “Where values is being added”
It is where one spends the longest part of his living time.
Importance of workplace in one’s life On an average one spends his whole day as below: 25 – 30% time for sleeping 5 – 10% time for having food 15 – 25% time with family 5 – 15% time for travelling 35 – 40% time for workplace That is, about 50% of our wakeful time, we spend in our work place.
How is your work place ? Threatening (or) Inviting ? Lovable (or) not likeable ?
Can we make our workplace excellent, so that life is fulfilling and enjoyable. And we and our Organization become excellent…. Yes: We can through 5S
Your workplace should be an enabler: Because good workplace is what enables us to Earn our salaries Provide for our families Given good education to our children and improve our quality of life
“ I earn my salary by adding value to my Organization’s products”
Why is your Organization’s health important to you ? A healthy Organization showers prosperity on its employees. How does good workplace help your Organization? My workplace helps my organization to create products, manufacture products, reach them to customers, execute growth plans, provide service to customers. and
Create value for customers, our organization, my co-employees and all other stakeholders. If it is not in excellent condition, our organization would also not be.
Arrange all tools at one place it is easy to find any body
If it is good it would add more value to my Organization
Workplace becomes good through 5S “I don’t have to wait for materials I can get any tool I need in seconds and I don’t get tired through heat, sweat and poor ventilation:
How ? When: I organized my workplace well
This is 5S workplace
The physical and psychological “ENVIRONMENT” become better “ATMOSPHERE” became serene. Activities got “STREAMLINES” and “WASTAGE” where avoided
This enabled me and my organization to improve performance
0 0 0 0 0 0 0 0 0 0 0 0 0
00000000000000000 00000000000000000 00000000000000000 00000000000000000
Just as your body and attire indicate your personality, condition of your work place also indicates your personality
POSITIVE GROUP ENGAGED IN 5S
I consider my workplace as a symbol of myself and an extension of my personality, It is like the shirt I wear I do not like to wear dirty, smelling, bad quality shirt, it is below my dignity, same about my work place.
A highly negative, argumentative stressful shop floor is unhealthy
For a good physical & psychological environment We need Orderliness Good Organization Cleanliness No wastage of time No wastage of energy No wastage of material No pin picks like heat, poor ventilation, bad light, dust, dirt etc., As Also A Good Culture
5S Cannot be implemented with out proper culture
The Psychological environment should be………………….. Fulfilling Acceptable to the employees Satisfying Where you are seen as efficient and performing Where you feel proud to work
• I always look forward to have happy environment in my work place
•5S has made me take care and see that me and others are happy with what is going on in my workplace
•5S enables me and others to derive immense satisfaction
What is 5S ? “5S is a simple method for achieving excellence in your workplace using A FIVE STEPS approach” 1st S : Seiri (Sorting):- Ensure all needed items are available and keep away all not needed items. 2nd S : Seiton (Systematic arrangement):Arrange only needed items such that you can always access them easily. 3rd S: Seiso (Spic & Span):- Keep them neat and tidy. 4th S: Seiketsu (Standardization):- Make the best way the standard way; and do it every time in the standar way
5th S: Shitsuke (Self discipline):- Make this a habit Do not make the mistake of thinking that 5S covers only “THE PHYSICAL ENVORONMENT”
5S operates at The physical level The data level & The systems level
1) 2) 3)
Please note :5S starts with sorting Then arranging things systematically and neatly. 5S is not enforced by bosses. 5S learning is complete with having total self discipline and habit formation. 5S should be carried out in every nook and corner of the organization. No body is exempt from doing 5S it covers all levels. It is continuous activity carried out by you happily every day all your life. In fact 5S never ends Boss enforcing is not a 5s approach Good 5S 5S should be everybody’s concern & responsibility.
5S addresses :ABNORMALITIES :- “Whatever is not correct and not in the best condition” WASTAGES :- “Wastage does not added value to the product but adds to cost” TYPES OF WASTE :- (*) TIME (*) SPACE (*) MATERIAL All leading to money wastage An abnormality Is anything that is not as per design intention or
o o o
Expectation:Loose bolts and nuts. Damaged body, foundation, floor, wall etc., Dents, Scratches etc., Rusted components. Misalignment of materials, boxes etc., Unnecessarily open doors. Hanging and loose wires. Dirty switch boards. List abnormalities in Machine not running properly. your workplace continuously & Leakages. photograph them Noise, rattling, vibration. before and after Cobwebs, bad toilets. correction, so that the impact of correction Uneven movements. Etc.,
Physical abnormalities Damage Visible defect Rusting Incorrect position Bad appearance Leakages Screws/bolts/nuts Not tight Noise Vibration etc.,
Functional abnormalities Equipment not Functioning as per designing or customer requirements. Leading to problems Like unsafe operations low/high speed, poor output, over/under temperature, insufficient pressure. Heavy wear and tear etc.,
AVOIDABLE WASTAGE :Include following in your checklist: Power ………………… Power wastage Compressed air …… Compressed air wastage Water ………………… water wastage Steam ………………… steam wastage Oils ………………… oils wastage Lubricants …………… paint & Lubricants wastage Consumables Production material Any other special item in our factory
TIME WASTAGE :Time is Money! Idle time of machines. Time spent in searching for tools. Set-up times do not add value to product or customer. Chasing people, tools, materials. Searching for paper, documents and manuals. Waiting time for men and machines Re-work on which you repeat the time spent by man and machine.
Required additional avoidable capital investment, build in shop floor, stores, shelves etc., Can lead to accidents. Heads to inconvenience. Makes it difficult to trace required item in a bunch of items.
Space occupied by unwanted items can be utilized for keeping necessary items in an easy accessible fashion that maintains its quality and improves its life.
Unwanted material lying here and there, and deteriorating over time. Over – Production. Unnecessary inventory that adds to working capital. Defects. Excess material for processing, like too much rawmaterial for small components. Over-usage and leakage of consumable.
Material wastage costs a lot to the organization 5% saving in material cost can improve profit by 25 to 50% more
Example : -
If we think unsafe storage place for paints, oils and Lubricants. Do you realise how much value and money is lost because of such poor storage and upkeep besides begin a safety hazard.
2) This is an out door storage for rawmaterials like sheets, rods, angles, channels etc., will they not get corroded and lose their properties over time? Do you agree this should be improved.
5) a. b. c. d.
Prepare the list of items that are needed in your workplace. List out needed items that are not available. Ensure availability of needed items. List out unnecessary items available in your workplace. Segregate unnecessary items into Those needed less frequently or rarely. Needed by some other department. Not sure whether needed or not & Not needed / scrap
Get rid of unnecessary items from the workplace by giving away to those in need. Creating a special location (Red tag area) for doubtful items for decision making. Keeping rarely needed items easily accessible in stores and disporting off unwanted items. Present unnecessary items from entering. Do not provide any space for unnecessary items. TARGETS OF SEIRI:(A).What should be available:Items that are needed every day for ensuring product and efficient working. Items needed in an emergency. Items that are needed every day for good product and efficient working.
Unwanted items Superfluous items Idle equipment / tools Unsold products Items that are not needed in your workplace Items kept because there is no pace available else where
I always ask my self
# Do I have items I don’t need at my workplace #Which not needed items are there preventing me from working well. # Do I have items at my place that others need and that make them struggle to perform well?
There may be items that have good value but are not needed at my work place. It is better to ask my superior. “what should I do with them:
•Be careful while discarding items
While doing Seiri:In your enthusiasm to so 5S well ensure that you or the organization do not get into difficulties later on by errors in execution.
Take the help of higher authorities to decide on doubtful items. One should not be in trouble at a later because of a needed item being discarded.
Place for every thing & Every thing in its place
Easy accessibility of needed items
SEITON IS:Arranging segregated items in a standard fashion Any one can retrieve any item, any time with minimum search time and They do not get damaged or dysfunctional through careless storage.
STEPS OF SEITON:1) Do SEIRI thoroughly throw away items. Don’t include them in SEITON. 2) Decide where to locate each necessary items. 3) Decide how to locate these items so that they can be “easily traced” and also “do not get damaged” or “Deteriorated”
All items needed by the operator such as tools, jigs, fixtures, consumables, production items bins, etc.,
Target of SEITON
Nearness of storage location according to frequency of usage
Storage method (Packing) as per the life and safety requirements of the item and its users.
On the item
Provide Name, code & Add
All the place of storage, including its temporary location
In a common record, register plus computer.
How to record address:No ambiguity should be there on what is the item No confusion between different items. The permanent, as well as present location should be clear. A standardized unique code no. and name should be given for each item. Store with good addressing system appropriate labels/ stickers; addresses; names; carefully numbered racks and well- designed code number for items. See also that the data is stored in a computer and recorded in a register.
SEISO : Spic & :Spam Attitude & Behaviour:- are the sources of all dirtiness / untidiness It is necessary to train our behaviour to reject untidiness and correct it all the time. Learn to react to all that is not up to the mark and correct it without waiting for some one else to do it. Often we are not keen to handle cleaning equipment ourselves as it is distasteful. Leader has to show the way by himself carrying out seiso. Defects are revealed white cleaning. Mend them as soon as you notice them. Is it right that some one spoils the workplace and some one else cleans it ? That is not the way to achieve workplace excellence.
SEISO : Spic & Spam
Every one has to contribute to maintain his/ her workplace clean and tidy. While doing SEISO learn to eliminate all root causes of dust and dirt
1) 2) 3)
STPS OF SEISO: Identify which parts to be cleaned each shift / twice daily, weekly, monthly etc., Plan for systematic daily or periodic cleaning of all nooks and corners of the zone/ whole plant. Prepare a cleaning calendar and follow it regularly
5) 6) 7) 8)
Ensure cleaning material and cleaning tools are available at any accessible place. Carry out SEISO systematically. Attend to defects that are revealed while cleaning. Identify and remove the root causes of such defects. Identify and remove the root causes of dust and dirt.
Cleanliness Cleanliness Good Psychological environment Targets of SEISO
Safety and removing hazardous
Exposing hidden defects Timely correction of defects
TARGETS OF SEISO:1) Clean: Surfaces Sides Insides All around
2) Expose: Hidden defects while cleaning cracks, rusting damages.
3) Safety: Identify safety hazards like loose foundation, excessive vibration etc.,
4) Hygienic: Look out for bad smell, pollution ensure ventilation, lighting etc.,
5) Timeliness; Did you discover and rectify problems before it was too late ?
6) Psychological environment: Is the organizational environment conductive to do all the above?
•Sreedhar always produces in best quality and highest productivity let us see how he does it and accept is as the “STANDARD:
Maximize benefits. (when every one does a thing the standard way. WASTE and COST are minimal
Do not impose standards that are difficult to stick to seiketsu standardizes the best results achieved through seiri, seiton and seiso. Continuous repetition of first 3S will create a work place that is
•SAFE, COST EFFECTIVE, INVITING, ACCEPTABLE, NOT FRUSTRATING TO WORK WITH AND EXCELLENT IN ALL RESPECTS.
Through Seiketsu:Set standards for all that is repetitive.
Hone and polish these standards continuously.
Develop cleaning calendars, visual controls, check lists
Learn to expose problems.
Propagate/educate regarding safety measures, and Conserve resources.
1) 2) 3)
STEPS OF SEIKETSU: Identify the way different people are doing an activity. Discuss and choose the best way Make this the standard method once everyone accepts it. Convert this into a written standard, giving a reference code number. Ensure that everyone does the same work only as per the standard. After accepting it as the standard, review it from time to time and improve it as necessary. Identify the weaknesses in the standard and upgrade them.
TARGETS OF SEIKETSU:-
FREQUENCY: Those elements of work, which are carried out frequently need to be standardized so that time taken and consumption of other resources can be minimized. SAFETY: Work done wrongly can lead to accidents. COST: Work in many different ways as per each individual’s idea can lead to high wastage and cost FOCUS OF SEIKETSU: (a). ITEMS, (b). PROCESSES, (c). SYSTEMS 1) Loose top cover in a pressure vessel is “DANGEROUS” 2) Loose electric wire, poor plugging and bad jointing leads to electric shock and injury to people.
5S and The improvement process become a habit and you carry it an every day
SHITSUKE:- Propagates sustenance of 5S through habit formation.
Human nature is to ignore the rules. When 5S becomes a habit , one is directed internally and rule takes over automatically. The is no need to supervise, inspect and correct your activities.
DO EACH ACTIVITY AS PER THE STANDARD AND FOLLOW ALL STEPS.
RULE IS A RULE AND RULE FOR ALL Rule is to be formulated by arriving at a consensus of everyone so that all objections and concerns are taken into account.
Rule is to be easily understood in 10 seconds perfectly through “VISUAL CONTROLS”. Otherwise there may be errors in following it. One should feel for the rule and follow it oneself pressure from the top.
A rule is not supposed to be broken by anyone every relevant person should be covered by the rule.
STEPS OF SHITSUKE (All self governed steps): I know 5S and follow it EVERY DAY from the time of starting to work and repeating it when I close for the day. I keep myself tidy and follow the dress code. I do my routine activities as per the STANDARDS only. I keep my workplace SPIC & SPAN. I strictly follow safety rules. I am always searching for “ABNORMALITIES” I am always looking for how to “SOLVE” them. EVERY ONE IS 5S PERSON I am 5S PERSON
Targets of SHITSUKE EVERY PLACE IS A 5S PLACE
Check list:- Prepare a check list for maintaining your work place while starting and before leaving your workplace. Check…… Workplace cleaned before / after shift Previously listed “ABNORMALITIES” are corrected. No unwanted material in the workplace. Inspection of the machine and tools, jigs and fixtures before starting. Checking for lubrication, leakages, loose nuts / bolts, noise, vibration etc., All tools ready at the workplace (or back to their place of storage). Safety equipment like hand gloves, safety spectacles, safety shoes, etc are on Toilet cleanliness etc.,
SELF AUDIT(CONDUCT SELF-AUDIT): Your mid is your judge. Ask it whether you have done it right Daily 5 Minutes 5S In the initial stage it takes time to follow 5S once it is sustained it becomes 5 minutes 5S daily.
Eh! Now a days I love my machine like my child. I take care of its needs. I clean it up and make it look good. It loves me too. It never troubles me no misbehavior, no breakdowns.
Why con’t I extended 5S to my home?
Yes, I extended 5s to my home. My wife became much more loving and cooperative after that