Execution Education Programme on 5S House Keeping Applied to Corprates

by Prof. T.Sivanandam
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Quality of Life

Va lu e

Sk ills
Quality of Life

Quality of Life

Knowledge
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Leadership

5Ss - Five Keys to Total Quality Environment

Seiri Seiton Seiso Sorting Out Systematic Arrangement Spic and Span Standardisation Self - Discipline

Seiketsu Shitsuke -

Why 5S
Creating a Healthier Corporate Climate. Enhancing Operational Control of Process. Reducing Downtime. Safety Establishing Ambience for Quality Less tension, more productivity Visibility is high Detect abnormalities Optimize space utilisation Avoid hastle for searching
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Seiri (Sorting Out)

Meaning : Putting things in order, Sorting, Removing what is not needed, Keeping what is needed. Aims: Establish criteria and stick to them in eliminating the unnecessary. Practice stratification management to set priorities. Be able to deal with the causes of filth. ...contd.

Activities : Eliminating the unnecessary, Dealing with the causes of filth. Kaizen and standardization based on fundamentals, Principles : Stratification management and dealing with the causes.

Seiri (Sorting Out)

Typical Activities Throw out the things you do not need Deal with the causes of dirt and leaks Housecleaning Inspect covers & through to prevent leakage & scatter Clean the grounds Organize the warehouse Eliminate grime and burrs

Functional Layout
Things we dont use: discard Things we dont use but want to have on hand just-in-case: keep as contingency items. Things we use only infrequently: store somewhere far away. Things we use sometimes: store in workplace Things we use frequently: keep at workplace or on the person.

Seiton (Systematic Arrangement)

Meaning : Placing things so that people can easily reach what they need whenever they need it Aims : A neat looking workplace, efficient (including quality and safety) layout and placement, raising productivity by eliminating the waste of looking for things. ...contd.

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Activities: Functional storage based upon the 5Ws and the 1H, practice and competition in putting things away and getting them out, neaten workplace & equipment, eliminating the waste of looking for things. Principles: Functional storage & eliminating the need to look for things.

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Seiton (Systematic Arrangement)

Typical Activities : Everything has a clearly designated place Thirty-second storage and retrieval Filing standards Zoning and placement marks Eliminate lids and locks ...contd.
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Steps:
Analyse present situation Fix storage place Get rid off unnecessary items Decide proper storage layout Make retrieval easy Improve procedures
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Seiso (Spic and Span)

Typical Activities : Quick 5S drills Make cleaning and inspection easier Sparkling clean campaigns Everybody is a janitor (priority 5S) Perform cleaning inspections & correct minor problems Clean even the places most people do not notice

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Problems Discovered During Cleaning

Others (30) Inadequate Grime and dirt wiring clogging (81) motor Dirty filters problems Dirty Motor fans Dirt inside electrical 303 prob Breakage (7) panels treated Fan belts 353 prob Inadequate Pressure problems discoverd lubrication (78) Old pipes etc. Couplings Low oil levels Loose fittings (87) Oil Leakage Couplings Friction on moving parts
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Seiso (Spic and Span)

Typical Activities : Quick 5S drills Make cleaning and inspection easier Sparkling clean campaigns Everybody is a janitor (priority 5S) Perform cleaning inspections & correct minor problems Clean even the places most people do not notice

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Seiketsu (Standardisation)
Meaning: Maintaining cleanliness, after cleaning eliminating germs & strains Aims: Management standards for maintaining the 5Ss Innovative visible management so that abnormalities show up
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Activities: Innovative visible management, early detection and early action, Tools (e.g., manuals) for maintaining standardization, color coding. Principles: Visual management and 5S standardization

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Color-coded pipes Oil labels Warning colors Fire extinguisher signs Foolproofing Responsibility labels Wire management Inspection marks Precision - Maintenance labels
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Seiketsu (Standardisation)
Typical Activities : Okay marks Danger zones marked on meters Thermal labels Directional markings Belt-size labels open-and-shut directional labels Voltage labels ...contd.

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Shitsuke (Self - Discipline)

Typical Activities : All-together cleaning Exercise time Pick-up practice Wear your safety shoes Public-space management ...contd.
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Activities: One - minute 5S, communication and feedback, individual responsibility, practicing good habits. Principles: Habit formation and a disciplined work place. `

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Practice dealing with emergencies Individual responsibility Telephone and communication practice 5S manuals Seeing is believing

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Shitsuke (Self - Discipline)

Typical Activities : All-together cleaning Exercise time Pick-up practice Wear your safety shoes Public-space management ...contd.
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Three-minute 5S
Manufacturing Check your own clothing Check leakage, pick up parts, trash on floor Wipe labels, position markings Realign anything out of place Administration Check your own clothing Check leakage, pick up parts, trash on floor Straighten up your desk Check desks and filing cabinets and fix them if they are out of place

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Five-minute 5S
Manufacturing Clean plates and labels Wipe the main parts of the machinery Ensure that bits and tools are in place Get rid of anything that is not needed Administration Get rid of unwanted things in your draw Check desks and filing cabinets and fix them if they are out of place

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Ten-minute 5S
Manufacturing Clean up key parts and other places of machines Fix labels that are coming off. Clean the floor Get rid of trash from trash bins. Administration Get rid of unwanted things on top of filing cabinets, bookcases Clean the floor Check to see if the files are numbered in proper order Check to see the number of pens, etc.

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5S CHECKLIST (PRODUCTION DEPT) 5S NO 1

Section Marks /100

Checker Previous marks /100 Date: MARKS 0 1 2 3 4

CHECKING ITEM Parts of materials

EVALUATION CRITERIA No unnecessary stock items or work-in progress.

Cleaning (/20)

Machines and equipment All machines and pieces of equipment are in regular use Jigs, tools and molds All jigs, tools, molds, cutting tools and fittings are in regular use All unnecessary items can be distinguished at a glance There are clear standards for eliminating excess

4 5

Visual control Standards for disposal

Contd

5S

NO

CHECKING ITEM

EVALUATION CRITERIA 0

MARKS 1 2 3 4

Storage labels

Organizing (/20)

There are labels to indicate different districts and subdistricts All shelves and items in storage are labeled clearly
There are clear indications of maximum and minimum stock quantities

Labels shelves and stored items Quantity indicators

Dividing lines

Dividing lines are all clear and all painted white Storage of jigs and tools is well organized for ease of extraction and return
Contd 29

10 Jigs and tools

5S

NO 11 Floor

CHECKING ITEM

EVALUATION CRITERIA 0 The floor is always s clean and shining Machines are kept clean Cleaning and checking are regarded as the same thing There is a rotation or shift systems for cleaning Sweeping and whipping are regarded as habitual activities The air is clean odorless and free of cigarette smoke The angel and intensity of illumination are appropriate No body is wearing a dirty uniform The general environment is good. Including color, air, lighting, etc.,
There is a system for maintaining clearing-up. Organizing and cleaning.

MARKS 1 2 3 4

Standardization (/20) Cleaning (/20)

12 Machines 13 Cleaning and checking 14 Cleaning responsibilities 15 Habitual cleaning 16 Ventilation 17 Lighting 18 Uniforms 19 Environment 20 The first three steps

Contd 30

5S

NO

CHECKING ITEM

EVALUATION CRITERIA 0 1

MARKS 2 3 4

Training and Discipline (/20)

21 Clothing rules

The rules are adhered to

22 Interaction of people

There is a pleasant general atmosphere. People exchange greetings etc.,

23 Meeting times and break Everyone makes an effort to be times punctual 24 Telephone manners Everyone states their business clearly. Politely and succinctly. All rules and regulations are strictly observed

25 Rules and regulations

Total

Check dispersal of marks (total for each column)

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5S Radar Chart
1S Cleaning-up
20 15 10 5 0

5S Training & Discipline

2S Organizing

4S Standardizing
100 80 60 40 20

3S Cleaning

Marks Month

Graph

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Creativity
Positive Factors
Enquiring attitude Positive Attitude Experience Encouragement Reading Games / puzzles Powerful Radar Qualities

Negative Factors
Negative attitude Emotion Timidity Self Discouragement

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Braining Storming
Leader should observe the following during brainstorming No criticism or comment allowed More Quantitative than Quality Allow Cross fertilisation of ideas Encourage participant to come out with Wild ideas Knowledge has constraints Imagination has no constraints
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