An overview of Lean & 5S for Attaining

Safety Culture
 Lean Manufacturing
• Lean manufacturing or lean production, often simply
"lean", is a systematic method for waste minimization
("Muda") within a manufacturing system without
sacrificing quality and productivity.

•  Lean also takes into account waste created through

overburden ("Muri") and waste created through
unevenness in work loads ("Mura").

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Figure 1. Lean Manufacturing Tools
Benefits of Lean Manufacturing

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 Lean Manufacturing Six Sigma (DMAIC)
• Today lean manufacturing or lean • Six Sigma has been
thinking is viewed as a formidable considered as a business
strategic weapon to succeed in
competitive markets.
strategy that employs a well
structured continuous
• Lean Thinking perception is improvement methodology
considered as a successful business to tackle process variability
strategy, employs minimization of and drive out waste from the
process variability and non value process with the phases
added activity (waste) using value
called DMAIC (Define,
stream mapping.
Measure, Analyze, Improve
• Lean manufacturing can be defined and Control)
as: “ A systematic approach to
identifying and elimination of waste
through continuous improvement by
flowing the product at pull of
customer in pursuit of perfection.
5S is a Housekeeping Methodology which can be applied to the
office as well as the shop floor workstations. It is directed towards
organization, cleanliness, and standardization .
 The five Ss are derived from five Japanese words which are Seiri (Sort), Seiton
(Straighten), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain).

The 5-S practice is a technique used to establish and maintain

quality and self environment in an organization.

Sort Separate What is unnecessary?

Set in Order Organize ( A Place for Everything and Everything in its
Place)

Shine Clean it up.

Standardize Establish Standard Operating Procedures
Sustain Develop Long Lasting Habits. (Self- Discipline)
 5S is a Lean Tool
Sort means removing unneeded items from the work area and clean
up the work area .

Set in order is to determine the location and quantity of needed

items .

Shine involves cleaning and improving the workplace, identifying

irregularities .

Standardize documents and standardizes the work method, using

standard tools and procedures .

Sustain is to maintain improvement, enabling employees to develop

good work habits, and finally integrating 5S into the corporate
culture.
Result:
5S builds a clear understanding among employees as to
how work should be done. It also installs a sense of
ownership of the process among employees.

Housekeeping has a key objective i.e. safety.

It can reduce tripping and fire hazards.

Thus, if 5S is properly planned and executed in

workplace, safety culture can be achieved within
defined time frame.
Why we have to Include Safety in 6S ?
We know that Safety is the topmost priority in every
workplace. Having a safe and clean working environment
leads to : 
Create a positive impact on productivity and quality; 
encourage a stress-free and healthy atmosphere where
workers can feel safe and secure; and
make it easy to recognize potential hazards and install
safety controls. 
 Safety Step of [6 S].
The first step to safety is identifying existing hazards and those
which are likely to be present in the workplace. All employees must
be aware of the different types of workplace hazards  and evaluate
these hazards through risk assessments. These prerequisite
methods carry out standard safety procedures and necessary controls
to reduce or eliminate these hazards.
Workers should also wear appropriate personal protective
equipment (PPE)  as an additional protection to hazards which are
difficult to control or can not be eliminated. The  use of PPE must
be checked and other safety protocols must be disseminated to all
workers through training and  toolbox meetings.
Achieving 100% safety is never an easy task, but through
incorporating safety to the original 5S method—and Kaizen. At the
same time, workers habitually contribute to the overall workplace
safety.
 Safety impact of a 5S Program.

****Sustain is to maintain improvement, enabling employees to develop

good work habits, and finally integrating 5S into the corporate culture.
“5S” Implementation Procedures
Figure 2. “5S” - Implementation through PDCA Methods
 How to Sustain 5S?
Get management commitment

Get everyone involved

Promote 5s in the organization

Do it all the way

Gemba walk by Head ( Mr. A.Kallarpiran)

Conduct monthly review by 5S committee

Use 5S as a platform to launch other Continuous

Improvement Programme / initiatives.
Quality Circle (QC) – Focused on
improvements in the workplace and service
process.
 Cause-and-Effect Diagrams

• Called Fishbone Diagram

• Focused on solving identified quality problem.
 Flowcharts
• Used to document the detailed steps in a process
• Often the first step in Process Re-Engineering