Asao svacCta ijaqao ijaqao È vasao laxmaI itqao itqao È È

Seiri Seiton Seiso Seiketsu Shitsuke

S.B.Shinde -- Sourcing Quality Assurance

Quality Improvements

INDIA
1950 1960 1970 1980

S.B.Shinde -- Sourcing Quality Assurance

1. 5S Principles
 Elimination of waste  Every body is involved, Cooperative effort  Attack root cause  Human being is not infalliable
S.B.Shinde -- Sourcing Quality Assurance

2. Objectives
 Improve housekeeping  Make every individual responsible for housekeeping  Beautify by simple means  Productivity improvement by saving time, space etc.
S.B.Shinde -- Sourcing Quality Assurance

3. 5S’s
• Seiri • Seiton • Seiso
- Sorting
- Systematic arrangement

- Cleaning Inspection while cleaning

• Seiketsu - Standardization • Shitsuke - Self Discipline
S.B.Shinde -- Sourcing Quality Assurance

They are features which are common to all places and are the indicators of how well an organization is functioning. S. we can’t do any other work efficiently.Shinde -.B.Sourcing Quality Assurance .5S If we do not do 5S.

SEIRI = Sorting Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items Establish a criteria for eliminating unwanted items Eliminate unwanted items either by disposing them or by relocating them. Area saved or percentage of space available Activity Success Indicator S.Sourcing Quality Assurance .Shinde -.B.

Item is not needed 2.Sourcing Quality Assurance .Shinde -.B.Seiri = Sorting What is unnecessary 1. Item is needed however quantity in stock is more than what is needed for consumption in near future 3. Contingency Parts Critically decide the quantity of contingency parts to be retained and criteria for such parts S.

Shinde -.Sourcing Quality Assurance .B.Organization Frequency of use Storage Method LOW *Things you have not used Throw them out in the past one year *Things you have used once Store at distance OR in the last 6-12 months Keep in store *Things you have used only Store it in central place once in the last 2-6 months in your zone *Things used more than once Store it in central place a month in your zone HIGH *Things used once a week Store near the workplace *Things used daily or hourly Store near the workplace S.

Seiri = Sorting Identifying unnecessary 1.Shinde -..Sourcing Quality Assurance . S.B. Parts & Work in Process (WIP) • Things fallen back behind the machine or rolled under it • Broken items inside the machine • Things under the racks/ platform • Extra WIP • Stock of rejected items • Items accumulated over period for rework • Material awaiting disposal decision • Material brought for some trial. still lying even after trial • Small qty of material no longer in use Contd.

B. S. liners. Toolings. bits. Contingency Parts • Many times storage place for contingency parts become a last refuge for broken parts. Measuring devices • Old jigs. may be lying • Measuring equipment not required for the operation being performed . surplus items and things nobody is likely to use Contd. toggles etc. etc. are lying after trial • Worn out items like bushes. lying • Broken tools.Seiri = Sorting Identifying unnecessary 2.Shinde -. tools not in use are lying • Modified tools. is lying 3.. tooling for trial. Tools.Sourcing Quality Assurance .

Sourcing Quality Assurance . Walls and Bulletin Boards • Old out dated notices which have lost their relevance • Posters or bulletins on wall • Dust. 7. like surplus.. remains of torn notices. cell tape pieces Contd. 5. Passages and Corners • Dust. Shelves and Lockers • Shelves and lockers tends to collect things that nobody ever uses . S. spittoon etc.Seiri = Sorting Identifying unnecessary 4. broken items etc. material not required seem to gather in corner 6.B. Besides Pillars and under the stairs • These places tends to collect junk.Shinde -.

small items • Even tools.Floor.B. outdated.Sourcing Quality Assurance . temporary files pile up S. tooling Items dropped on the floor are never picked 9.Shinde -.Computer Hard Disk • Many unwanted. Pits. covers • Packing material • Hardware items . Partitions • Defective parts • Protection caps.Seiri = Sorting Identifying unnecessary 8.

Seiri = Sorting Improvement methods 1.Shinde -. How to make and use category wise grouping 2.B. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system eg. S.Sourcing Quality Assurance . How to perform Seiri (sorting) 3. Check List A check sheet is used to decide what sort of main system and sub system are necessary. Operational Analysis Preparing the sequence of operations for system eg.

Sourcing Quality Assurance .Shinde -.B.Seiri = Sorting Dealing with papers How to reduce papers on your table ? 1. Make a single pile of papers 2. Go through them and sort in following categories a) Immediate action b) Low priority c) Pending d) Reading material e) For information S.

Shinde -.Sourcing Quality Assurance .B.Seiri = Sorting Dealing with papers How to reduce papers on your table ? 4 D Principle DO DELEGATE DELAY DUMP S.

Sourcing Quality Assurance .Shinde -.Functional storage .SEITION = Systematic Arrangement Meaning Activity To determine type of storage and layout that will ensure easy accessibility for everyone .Time saved in searching Indicator .Creating place for everything and putting everything in its place Success . .Time saved in material handling S.B.

B. parts supply to assembly line.SEITION = Systematic Arrangement The main target areas for Seri-Seiton improvement are : Tool-setting and preparation operations. peak time problems etc.Shinde -.Sourcing Quality Assurance . Improvement Methods Kit Method / Assembly box method / Outside tool setting Cassettisation / Parallel operations / Changes in assignment method S. line balancing and process planning.

Shinde -.Seiton = Systematic Arrangement How to achieve Systematic Arrangement ? • Decide where things belong • Decide how things should be put away • Obey the Put away rules S.Sourcing Quality Assurance .B.

Standardize Nomenclature • Decide how things should be put away . Label both item and location .Determine an analytical method of storage .Store material functionally .B.Sourcing Quality Assurance .Name & locations to everything.Seiton = Systematic Arrangement How to achieve Systematic Arrangement ? • Decide where things belong . S..Prevent mistakes with coding by shapes & colour contd.Shinde -.

Put the things back to their location after their use S.Shinde -.Follow first in first out rule .B.Seiton = Systematic Arrangement How to achieve Systematic Arrangement ? • Decide how things should be put away .Sourcing Quality Assurance . then store them separately.If two identical items are to be located. • Obey the rules . colour code them.

Sourcing Quality Assurance .Shinde -.B.Seiton = Systematic Arrangement USE : 1 ) Signboards 2) Colour codes 3) Outline markings 4) Labels S.

Shinde -.Sourcing Quality Assurance .Seiton = Systematic Arrangement Functional Storage S.B.

Seiton = Systematic Arrangement Usage • Store frequently used material Frequency near the workplace and less frequently at some distance Weight & Shape of the Material • Heavy material should be stored at lower levels/layers Place directly on the material handling device for ease of handling Functional Storage S.Shinde -.Sourcing Quality Assurance .B.

Oil Seals • All items required for an operation may be stored in one location. Allen key.B.Shinde -. Eg. spanner etc hand tools required for setting m/c Operation Wise Functional Storage S. Allen Screws.Seiton = Systematic Arrangement Category • Same category of material may be stored in one location. Eg.Sourcing Quality Assurance .

Machines • Stands and shelves .B.Provide casters where necessary so that it can be moved S. aisles.Follow straight line.Shinde -.Nothing shall be kept outside the boundaries .Mark boundaries of dept.. right angle rule . size .Seiton = Systematic Arrangement • Outlining and Placement Marks .Keep only required number of stands and shelves .Standardize height.Sourcing Quality Assurance .

Seiton = Systematic Arrangement • Wires and Ducts .When there are multiple connections . label them and make sure that they are in straight line /right angle and firmly anchored • Machine-tools & Tools .Sourcing Quality Assurance .Colour code .B.bundle the wires.Put the tools in the order you need them .Try to eliminate some hand tools by permanently attaching it to the bolt head S.Shinde -.Location of the tool should be such that it can be put away with one hand .

Seiton = Systematic Arrangement • Blades.Store them in the protected place • WIP.Maintain these things regularly by applying rust preventive. Other important consumables .Sourcing Quality Assurance . they do not get rusty and they are not mislabeled S.Work In Process .B.Shinde -.Designate a place for each component/part . oiling etc.Decide on how much quantity to be stored . . Dies.Ensure that there is no damage to good part during transit.

Label them.Safety aspects .B. leak. spillage • Instrumentation & Measuring Devices . show direction of flow S.Shinde -.Colour code for oil .Reduce number of oils used (Standardize) .Seiton = Systematic Arrangement • Oils . pollution.fire prevention.Sourcing Quality Assurance .

of accidents S. dust and other foreign matter.Sourcing Quality Assurance .Reduction in no.SEISO = Cleaning Meaning Cleaning trash.Reduction in machine down time .B. Cleaning as a form of Inspection Activity Success Indicator . filth.Shinde -.Inspection while cleaning .Keep workplace spotlessly clean .Finding minor problems with cleaning inspection .

Sourcing Quality Assurance .B. leakage etc. burrs.Shinde -. Cleaning should be viewed as a form of Visual Inspection • Preventive measures should be taken to tackle problems of dust. Root cause of the problem should be identified and it should be eliminated S. grim.Seiso = Cleaning • Here cleaning means more than just keeping things clean.

Sourcing Quality Assurance .B.Shinde -.Seiso = Cleaning Various Minor Defects = Trash = Dirt =Knocking = Loose parts = Leaks =Scattering =Skips =Curvature =Abrasion =Rust =Scratches =Eccentricity =Lurching =Abnormal =Vibration Movements =Abnormal =Heat =Abnormal Sounds smells =Faded colour =Hisses S.

B.Sourcing Quality Assurance .Seiso = Cleaning 5 Minutes Every day for cleaning • Devote 5 minutes everyday for cleaning your work area • Participation of everyone is required • Attack hard to clean places regularly S.Shinde -.

dirty or bent oil lines.Sourcing Quality Assurance . dirty oil.Seiso = Cleaning Cleaning-Inspection points for most equipment Grime. worn& torn ports etc. clogging. filter clogging. dust balls. leakage.Shinde -. S. rust. clogged drainage.B. Cleaning leakage etc. oil spillage. Oils No oil. Low oil.

S. loose parts. axles.B. welding detachment. heater. motors.Seiso = Cleaning Cleaning-Inspection points for most equipment Tightening Heat Loose bolts. friction Oil tanks.Sourcing Quality Assurance . control panels. vibration or bumping noise. washing/ cleaning water. wiring etc.Shinde -. bearing.

Sourcing Quality Assurance . crack dial of various pre. S.Shinde -.Seiso = Cleaning Cleaning-Inspection points for most equipment Breakage. cracks. wires are broken or crack. handle has come off. Cracks Breakage. wire joints come off. broken switches.B. dent on sliding parts. gauges. meters etc.

Shinde -. Hydraulic oil tank.Sourcing Quality Assurance . cylinders etc. filters. air valves.B. hoses. meters.Seiso = Cleaning Function wise Cleaning check list of equipment Pneumatics Compressed Air lines. oil valves. gauges. reservoirs etc. filters. pumps. connections. Hydraulics S.

fan belt. couplings. pulleys.Shinde -.B.Seiso = Cleaning Function wise Cleaning check list of equipment Motor fan. wiring. pump Power Train bearings etc. Electrical Control panel. S. ducts. switch. chains. Mech & Joints. sensors. lamps.Sourcing Quality Assurance . fuses etc. light.

gauges. dies.Sourcing Quality Assurance . etc. Furnaces.Shinde -. S.Seiso = Cleaning Function wise Cleaning check list of equipment Toolings Equipment Specific Tools. rollers. etc.B. measuring instruments. chutes. CNC machines. fixtures.

workplace and details of how to maintain the norm (Procedure) . clean.Sourcing Quality Assurance .B.Shinde -.Innovative visual management .SEIKETSU = Standardization Meaning Setting up standards / Norms for a neat.Colour coding .Early detection of problem and early action Increase in 5S indicator Activity Success Indicator S.

SEIKETSU = Standardization Tools used for analysis : MTTR MTBF OEE S.Shinde -.Sourcing Quality Assurance .B.

Seiketsu = Standardization • Regularizing 5S activities so that abnormalities are revealed • Make it easy for everyone to identify the state of normal or abnormal condition • For maintaining previous 3S.Sourcing Quality Assurance .B. deploy visual management S.Shinde -.

It is consistency that is difficult. so that everybody will know that there is some problem.Seiketsu = Standardization • It has been estimated by scientific study that 60% of all human activities starts with sight • 5S is easy to do once.Sourcing Quality Assurance .Shinde -. That is why Visual Management is so important.B. Visual Management S.

Sourcing Quality Assurance .Shinde -.Seiketsu = Standardization What visual control communicates ? It grabs one or more of our senses in order to • • • • Alert us to an abnormality Help us recover quickly Promote adherence and prevention Enable successful self management S.B.

Seiketsu = Standardization Some methods for visual communication        Colour coding Use of Labels Danger alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators S.Sourcing Quality Assurance .B.Shinde -.

Sourcing Quality Assurance .B.Seiketsu = Standardization Some methods for visual communication Labels  Precision management labels  Inspection labels  Temperature labels  Responsibility labels S.Shinde -.

Everyone can tell what is right and what is wrong 4.Seiketsu = Standardization Points to remember in making visual c control tools 1.Sourcing Quality Assurance . Work place should look brighter & orderly S. Make them easy to see from distance 2. Anybody can follow them and make necessary corrections easily 5.Shinde -. Put the display on the things 3.B.

Speed indicator  Direction arrows  Electric danger sign etc.Petrol indicator . S.B.Seiketsu = Standardization Some everyday visual management examples  Traffic signal  Zebra crossing  In car .Sourcing Quality Assurance .Shinde -.

B.Seiketsu = Standardization Some visual communication signs S.Shinde -.Sourcing Quality Assurance .

Regular audits and aiming for higher level High employee morale Involvement of all people S.Shinde -.B.Participation of everyone in developing good habits .Sourcing Quality Assurance .SHITSUKE = Self Discipline Meaning Every one sticks to the rule and makes it a habit Activity Success Indicator .

S.SHITSUKE = Self Discipline Activities : 5S Committee 5S Training 5S Competition / evaluation 5S Month Posters . Literature etc.Sourcing Quality Assurance .Shinde -.B.

Shinde -.B.Shitsuke = Self Discipline We need everyone to maintain 5S guidelines. Discipline is the Core of 5S S. we need to practice and repeat until it becomes a way of life.Sourcing Quality Assurance . To maintain DISCIPLINE.

Shitsuke = Self Discipline Discipline means making a steady habit of properly maintaining correct procedure.B. Time and effort involved in establishing proper arrangement and orderliness will be in vain if we do not have discipline to maintain it.Sourcing Quality Assurance . S.Shinde -.

Shinde -.B.Sourcing Quality Assurance .Shitsuke = Self Discipline Pledge It shall be my constant effort to maintain my workplace in good order by  Assigning a place for everything & keeping everything in its place  Sorting out unwanted material periodically & discarding them  Keeping my work area neat & clean everyday S.

Shinde -.B.S.Sourcing Quality Assurance .

Heat Treatment Area in Japan S.Shinde -.B.Sourcing Quality Assurance .

B.Shinde -.Sourcing Quality Assurance .Heat Treatment Area in Japan S.

Shinde -.Sourcing Quality Assurance .B.Heat Treatment Area in Japan S.

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