Before sort after sort

1. 5S
Principles

■ Elimination of wnste
■ Every body is
involved Co-op,erative
effort
■ Attack root cause
■ Human being is not
1
12
 1. 5S
Principles

■ Elimination of wnste
■ Every body is
involved Co-op,erative
effort
■ Attack root cause
■ Human being is not
1
12
Before sort after sort
 2. Objectives

■ Improve housekeeping
■ Make every individual
r,esponsible for
housekeeping
■ Beautify b·y simple
means
■ Pr·oductivity im1provement 13

by saving time,, space e t c

 3 'S'
Seiso : Cleaning
j
KIKEN KITSUI KITENOI

l l l
(DANGE (PROBLEM) (DIRT)
R)

Clean the surroundings !

 3 'S' - SEISO

3 'S' - We keep our body clean everyday

by having bath and cutting nails etc
Meaning Cleaning trash, filth, dust and other foreign
matter. Cleaning as a form of Inspection

Activity - Keep w9rkplace spotlessly clean

- Inspection while cleaning
- Finding minor problems wa.rh cleaning
inspection
Success
- Reduction in machine down time
Indicator - Reduction in no. of accidents

47
 5S - BASIC TRAINING

What is 5S
and
why do
we want to
do it?

ALOKSHARMA 22\06\2010
-
JapaAese Meaning :
:Dictionary meaning "to clean up" and
"getting rid of dirt and unclean items"
While cleaning potential defects such as
abrasion, damage, loose parts,
deformities, leaks temp., vibration,
abnormal sound ete. are revealed hence
Seise is Ins:lection -
48
 • Here cleaning means more than just keeping
=

things c]ean. Cleaning should

be viewed as a
form of Visual Inspection

• Preventive measures should be taken to

tackle problems of dust grim, burrs,. Ieaka,ge
e,tc. Root cause of the problem should be
identified and it s.hould be eliminated
•
49
 5 Minutes Every day for cleaning

• Devote 5 minutes everyday for cleaning your

work area

• Participation a,f everyone is required

• Attack hard to clean places regularly

•
50
EXAMPLE : PREPARE CHECKLIST FOR CLEANING

SL.No CHECKLIST TIC

K
1 Check Floors are clean

2 Check Work areas are clean

3 Check walls are clean ,

4 Check Pillars and Ceiling are clean

_
,

-
5 Check Windows are clean ,I'

-, -
-
6 Check Rooms and Electrical lights are clean - .¥

- 51
 Seiso Cycle
• BEFORE WORK, CLEAN AND INSPECT THE
MACHINERY TOOLS, IlGS & FIXTURES.
• BEGINNING OF WORK - DO TRIALS AND
STARTUP
• DURING OPERATION - CLEAN, INSPECT,
DISCOVER AND DEAL WITH ABNORMALITIES
• AFTER COMPLETION OF WORK - DISPOSE OFF
AND GET RID OF UN-NECESSARY THINGS
• SEISO IS A PART OF GOOD WORKMANSHIP
• SEISO IS AN IMPORTANT PRE-CURSOR
WITH5S
•
52
 Cleaning,-lnspection points for most
equipment.

Grime, clogging, dust balls, rust,

Cleaning leakage etc.

No oil, Low oil, leakage, filter clogging,

Oils dirty oil, dirty or bent oil lines, clogged
drainage, oil spillage, worn& torn ports
etc.

•
53
 Cleaning,-lnspection points for most
equipment.

Loose bolts, welding detachment,

Tightening loose parts, vibration or bumping
noise, friction

Heat Oil tanks, motors, heater, axles, control

panels, washing/ cleaning water,
bearing, wiring etc.

•
54
 Cleaning,-lnspection points for most
equipment.

Breakage, cracks, dent on sliding

Breakage, parts, handle has come off, broken
Cracks switches, wire joints come off, wires
are broken or crack, crack dial of
various pre. gauges, meters etc.

•
55
 Function wise Cleaning check fist
of e,quipment

Tools, fixtures, gauges, dies,

Tooling
measuring instruments, etc.

Equipment Furnaces, rollers, chutes,

CNC machines, etc.
Specific

•
58
Before shine after shine
Before shine after shine
 4 'S'
Seiketsu

s
 4' S' - SEIKETSU

4 'S' - In every human being the structure of fingers

are same I.e. Standardised. If it is not so, then we call it
is abnormal.
Meaning Setting up standards/ NoFL\TIS for a neat,
clean, workplace and details of how to
maintain the JlOTm (Procedure)

Activity - innovative visual maQagement

- Colour coding
- Early detection of problem and early action

Success Increase in 5S indicator

Indicator

63
Japanese
Meanirag
Dictionary :meaning
"unsoiled things, purity and cleanliness"
Clean manners ,
Clean cloths, clean politician
It is the proof that 3 S's are being faithfully
carried out.
64
Tools used for analysis :

MTTR : Mean Time To Repair\

Recover

MTIBF : Mean Time Between

failures OEE : Overall Equipment 65

 • Regularizing 55 activities so
that abnormalities are revealed
• Make it easy for everyone to
identify the state of normal or
abnormal condition

• For maintaining previous 35,

deploy visual management

•
66
 • Ithas been estimated by scientific
study that 60o/o of all human
activities starts with sight

• 55 is easy to do once. It is
consistency that is difficult. That is
why Visual Management is so
important, so that everybody will know
somethere is
that 1/isu-.l £l'!}Al1AtJeme11c
•
problem. 67
 What visual control communicat·es ?

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

•
68
Some methods for visual communication

Colour coding
Use of Labels
Danger alerts
Indication
Directional
where arrows/ marks
things 0

Transparent
should be put covers 0
Performance indicators 0
• 69
 Some methods for visual communication

Labels
Precision management labels
Inspection labels
Temperature labels
Responsibility labels

•
70
 Points to remember in making
vis,ual control tools
1. Make them easy to see from
distance
2. Put the display on the things
3. Everyone can tell what is right and
what is wrong
4. Anybody can follow them and make
necessary corrections easily
5. Work place should look brighter &
•
orderly 71
 Some everyday visual management
examples
♦ Tr a ff i c signal
♦ Zebra crossing
♦ In car - Petrol indicator
- Speed indicator
♦ Direction arrows
♦ Electric danger sign etc .

•
72
Same visual communication
e
signs 1\1111;/

- ---
/
--
--
- -..:

73
 5
'
S '
Shitsuke
ENSURE ...
►correct.
Procedure & Work Instruction are

►Standard are expressed in specific.

►Visual Aids are used.
►Train at all levels.
►Work ethics for effective management.
►Transparent & Discipline work culture.
 5' S' - SHITSUKE

5 'S' - Every human body has its

standard process which they
maintain.
Meaning Every one sticks to the rule and makes1.t a habjt

Activity - Participation of everyone in developing good

habits
- Regular audits a11d aiming for higher level

Success High employee morale

Indicator Involvement of all people

77
Japanese Meanirag :
Dictionary meaning is
"learnrng of the manners"
"having manners, dressing neatly'' OIR
"training children for good customs"

78
Activities :
5S Committee
5S Trairning
5S Competition 1
evaluation
5S MaAtll
Poste s , Literatare etc.
79
Shitsuke = Self
Discipline

80
Shitsuke = Self
Discipline

81
Shitsuke = Self Pledge
Discipline

Ill

82
 ORGANIZATION
• Departments into areas
• Coordinators at department
level
• Coordinator at each area level
• Training for all
• Audit each area and make action
check list
• Implement actions
• Audit and evaluation on continuous
basis
r- ,--j

=------,
During 5S
...----
i
 Some 5S Examples

After 5S - Cleaned, organized

and drawers labeled (less time
Before 5S and frustration hunting)
 5S Pictures

Before After
 5S Pictures

Before: Repair After

 5S Pictures

Before After
The Good, Bad and the Ugly
First the Bad and the Ugly - Life Without 5S
 ?
•

QI ....
=q ..
ch I cfi '-
11<:'1
 ..
. 4-cRsll

-- ::;:..-= - - .

I
a
'
THANK YOU
clapanese MeafPling :
:fhe Japanese meaning 0f "Seiri'' is
to straighten and contain.

- Get rid of waste and put it in order according

to rules

17
Seiri = Sorting What is
unnecessary "
'

1. Item is not needed

2. 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
•
20
Seiri = Sorting What is
unnecessary "
'

1. Item is not needed

2. 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
•
20
Seiri = Sorting Identifying unnecessary

1. 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..
22
Seiri = Sorting Identifying unnecessary
"
'
2. Tools, Tooling, Measuring devices
• Old jigs, tools not in use are lying
• Modified tools, tooling for trial, are lying after trial
• Worn out items like bushes, liners, toggles etc. lying
• Broken tools, bits, etc. may be lying
• Measuring equipment not required for the operation
being performed , is lying
3. Contingency Parts
• Many times storage place for contingency parts become
a last refuge for broken parts, surplus items and things
nobody is likely to use
•
Contd..
23
Seiri = Sorting Identifying unnecessary

a.Floor, Pits, Partitions

• Defective parts
• Protection caps, covers
• Packing material
• Hardware items, small items
• Even tools, tooling
Items dropped on the floor are never picked
9.Computer Hard Disk
• Many unwanted, outdated, temporary files pile up

•
25
Seiri = Sorting Improvement
methods
1. Flow Process Chart (Procedural Analysis)
Drawing a process flow chart for the system
e.g. How to make and use category wise grouping

2. Operational Analysis
Preparing the sequence of operations for system
e.g. 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.
•
26
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
27
Seiri = Sorting Dealing with papers

How to Reduce Papers

on Your Table ?

4 D Principle

DO
DELEGATE
DELAY
DUMP
Meanin Distittguish between necessary and unnecessary
g items and eliminate the unnecessary items

Activity Establish a criteria for eliminating unwanted item..

Eliminate unwanted items either by disposing
them or by relocating them.

Success Area saved or percentage of space available

Indicator

16
Japanese Meaning:
[Dictionary meaning of Seiton is ''to be correctly
prepared" and "to prepare correctly".
In short these means :
(a)arrange correctly in accordance with the correct method of
doing activities and
(b)make thorough preparations so that activities can be done
even if they occur abruptly

32
Meaning To determine type of storage and layout that
will ensure easy accessibility for everyone .

Activity - Functional storage

- Creating place foraeverything and putting
everything in its place

Success - Time saved in searching

Indicator - Time saved in mate.rial handling

31
Seiton = Systematic Arrangement

How to achieve Systematic Arrangement?

• Decide where things belong
- Standardize Nomenclature
- Determine an analytical method of storage
• Decide how things should be put away
- Name & locations to everything.
- Label both item and location
- Store material functionally
- Prevent mistakes with coding
by shapes & colour
c
•
o 34
Seiton = Systematic Arrangement

How to achieve Systematic Arrangement?

• Decide how things should be put away
- Follow (FIFO) first in first out rule
- If two identical items are to be located,
then store them separately,
- colour code them.

• Obey the rules

- Put the things back to their location
after their use
•
35
Seiton = Systematic Arrangement

USE:

1) Signboards

2) Colour codes

3) Outline markings

4) Labels

•
36
Seiton = Systematic Arrangement

Usage •Store frequently used

Frequency material near the workplace
and less frequently at some
distance
Weight & • Heavy material should be
stored at lower levels/layers
Shape of the
Place direct!y on the material
Material handling device for ease of
handling
J u o c t i o o n l .,Storn9e

•
37
Seiton = Systematic Arrangement

• Sarne category of material

Category may be stored in one location.
e.g, Allen Screws, Oil Seals
• All items required for an
Operation operation may be stored in
Wise one location.
e.g, Allen key, spanner etc
hand tools required for
setting rn/c
Junctionnl torn9e
3
8
Seiton = Systematic Arrangement

• Outlining and Placement Marks

- Mark boundaries of dept., aisles, Machines
- Follow straight line, right angle rule
- Nothing shall be kept outside the boundaries
. , S t a n d s and shelves
-Keep only required number of
stands and shelves
- Standardize height, size
- Provide casters where necessary so that
it can be moved
•
39
Seiton = Systematic Arrangement

• Wires and Ducts

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

• Blades, Dies, Other important consumables

- Store them in the protected place
- Maintain these things regularly by
applying rust preventive, oiling etc.
, • WIP- Work In Process
- Designate a place for each
component/part
- Decide on how much quantity to be
stored
- Ensure that there is no damage to good
part during transit, they do not get rusty
and they are not mislabeled
•
41
Seiton = Systematic Arrangement

• Oils
- Reduce number of oils used (Standardize)
- Colour code for oil
- Safety aspects - fire
prevention, pollution, leak,
spillage

• Instrumentation &
Measuring Devices
- Label them, show direction of
flow
•
42
Seiton = Systematic Arrangement

How to achieve Systematic Arrangement?

• Decide where things belong

• Decide how things should be put away

• Obey the Put away rules

•
33
 What is 5S?

5S represents 5 disciplines
for maintaining a visual workplace (visual controls and
information systems).

These are foundational to Kaizen (continuous

improvement) and a manufacturing strategy based
"Lean Manufacturing" (waste removing) concepts.

5S is one of the activities that will help ensure

any company's survival.
 What is 5S?

5S represents 5 disciplines
for maintaining a visual workplace (visual controls and
information systems).

These are foundational to Kaizen (continuous

improvement) and a manufacturing strategy based
"Lean Manufacturing" (waste removing) concepts.

5S is one of the activities that will help ensure

any company's survival.
 What is 5S?

5S represents 5 disciplines
for maintaining a visual workplace (visual controls and
information systems).

These are foundational to Kaizen (continuous

improvement) and a manufacturing strategy based
"Lean Manufacturing" (waste removing) concepts.

5S is one of the activities that will help ensure

any company's survival.
 5S
1. Sort - All unneeded tools, parts and supplies are
removed from the area
2. Set in Order - A place for everything and
everything is
in its place
3. Shine - The area is cleaned as the work is
performed
4. Standardize - Cleaning and identification methods are
consistently applied
5. Sustain - SS is a habit and is continually improved

Also - Work areas are safe and free of hazardous or

dangerous conditions
KAIZEN: What it is?
1) Process Improvement

2) Observation
3) Use of New Paradigms
4) Short Time
5) Zero Investment

6) Human Development &

Empowerment
7) Profits & Savings - Plenty
 IEN
ALWAYS GOOD
CONTINUAL IMPROVEMENT
CHANGE FOR THE BETTER
 KAIZEN IS A JOURNEY FROM:

+ EVENT TO CAUSE
-}- RESULT TO PROCESS
+GROSS TO MICRO
+ ENFORMENT TO INDUCEMENT
OF CHANGE OFCHANGE
KAIZEN IS CONTINUAL IMPROVEMENT

TIME
TIME

m
 KAIZEN: KNOW THE REALITY
THROUGH YOUR SENSE

OBSERVATION INTELLIGENCE
re:
PHYSICAL EFFORT

PARADIGM OF HIGH PRODUCTIVITY & QUALITY

KAIZEN AT GEMBA

GEMBA: PLACE OF WORK

GEMBA is where ...

►Value is added
► Actual work is done to meet customer
requirement

►Problems are solved

►Staff is responsible for providing
support,
not for giving instruction
The 'S' Japanese Word What is involved Objective

Segregate necessary from

unnecessary
SEIRI Remove what is not Saving and
lS required
(Sorting Out) recovering Space
Decide on frequency of
sorting

SEITON Arranging in order

Minimizing search
2S (Systematic Place for everything, time
Arrangement) Everything in its place
Inspecting for
Cleaning the work place/
SEISO problems
3S equipment
(spic and Span) Taking corrective
Attaining the warning
actions faster
bell
SEIKETSU Achieving higher
Working Methodology
4S (Standardizatio productivity and
(Procedures & WI) better quality
n)
SHITSUKE Forming the habit in form Doing it right at First
SS
(Self Discipline) of Training and Discipline Time
 ,.........J . ,I
l:'z@
4.S--J J W d.lJ'JJj -B
 l'S'-
11m
1
SEIRI
:i l11i\-.W>-!im S)Slt.
The Human Nasal passage
Respiratory
System -- Oral cavity
Pharynx
Larynx
.- Trachea
• Bronc
hi
Lung

·· . _.,.,
Ribs
·, Heart
,•'
,•'
/.I

1 'S' - Our respiratory system sorts oxygen and other

gases. And exhales other gases which are unwanted for our
body
 1S - SEIRI : SORTING

Sort for ... 1 'S'

Not Needed at All I
Needed but not
WANTED UNWANTED
Now Needed but not
here
Needed but not so much Quantity
 Organization
"
Frequency of use Storage Method '

*Things you have not used Throw them out

LOW
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
0 .
once in the last 2-6 months m your zone
(<} *Things used more than Store it in central place
once a month 1• n your zone

HIGH *Things used once a week Store near the workplace

*Things used daily or hourly Store near the workplace

•
L, '
 2 'S'
Seiton : Systeinatic Arrangeinent

Arranging things in systematic way

 2' S' - SEITON

f;
'
,/ )
t
('
;

2 'S' - In our body there is a fixed place for every organ.

 Some New Words
Lean Manufacturing-concepts that seek continuous
improvement by removing waste in processes
Some Japanese words one need to know:
Kaizen-(pronounced "kai zen") - Continual
improvement
Muda-(pronounced "moo da") - waste
Gemba-(pronounced "gim b a " ) - workplace
Kanban-(pronounced "kon bon") - Pull type inventory
control system. Items are only produced to meet
customer needs. The request to produce more is signaled
from an upstream operation and/or customer orders.
 What is 5S?

• Seiri - Sort (housekeeping)

• Seiton - Systematic Arrangement
(workplace organization)
• Seiso - Shine (Cleanup)
• Seiketsu - Standardize
• Shitsuke - Sustain (Self
Discipline)