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Aste Limination Eads To Ost Ptimization Anagement Xcellence: 5S Awareness W E L C O M E

The document discusses the 5S methodology for workplace organization and standardization. It begins with an overview of 5S and its benefits, then describes each of the 5S steps in detail: Sort, Set In Order, Shine, Standardize, and Sustain. Implementing 5S helps reduce waste, improve safety and quality, and increase productivity by organizing the workspace and establishing clear standards and responsibilities for cleanliness and organization. Before and after photos illustrate the transformation that results from applying the full 5S process.

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Swathi
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37 views

Aste Limination Eads To Ost Ptimization Anagement Xcellence: 5S Awareness W E L C O M E

The document discusses the 5S methodology for workplace organization and standardization. It begins with an overview of 5S and its benefits, then describes each of the 5S steps in detail: Sort, Set In Order, Shine, Standardize, and Sustain. Implementing 5S helps reduce waste, improve safety and quality, and increase productivity by organizing the workspace and establishing clear standards and responsibilities for cleanliness and organization. Before and after photos illustrate the transformation that results from applying the full 5S process.

Uploaded by

Swathi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 74

5S Awareness

Waste
Elimination
Leads to
Cost
Optimization &
Management
Excellence
Agenda

Brief History about 5S


What is 5S
Why do we practice the 5S
Meaning behind each “S”
How do we practice each “S”
Benefits of 5S
Why 5S?

• 5S Techniques are simple step by step approach to


work place improvement by reducing Non-Value adding
activities
• 5S is more “DO ITYOUR SELF” approach
A Brief Introduction About 5S

• 5S was Started in Japan in the year 1971


• 5S concept was popularized by Mr. Osada
• First 5S implemented company in the World-
TOYOTA, Japan.
• 5S was came to India in 1991
• TVS is the first 5S implemented company in India.
Seiso
Seiton Seiketsu

Seiri
5S
Shitsuke
1st S- “SORT”
(SERI)

What do you understand by this ???


In a work place where SEIRI is not Practiced

• There is always demand for more space

• Cluttered appearance

• Difficult to find information/items needed

• Leading to irritation in work areas

• Leading to mix-up of rejected /faulty items


• SEIRI implies organizing and clearing

• Sorting out the items as wanted and unwanted

• SEIRI is preferably done by personnel working in the area…WHY?

• SEIRI is easy to tell but difficult to follow why


SEIRI requires stratification of items as

• Regularly required

• Occasionally required

• Rarely required

• Items to be repaired

• Not required at all


PRIORITY FREQUENCY OF USE HOW TO USE
Low Less than once per Throw away
year Store away from
Once per year the workplace
Avg. Once per month Store together
Once per week but offline
Hourly Within arm’s
reach
High
Every Shift Within Short walk
Examples of SEIRI in factory

• Rejected items lying in a work place

• Unwanted jigs/Fixtures/Measuring instruments

• Outdated items

• Broken trolleys, pallets, bins

• End bits piled up at the end of works

• Out dated SOP’s

• Out dated drawings


Target Unnecessary items

UNSOLD DEFECTIVE
PRODUCTS PRODUCTS

UNUSED IDLE
ITEMS EQUIPMENT

SURPLUS EXCESS
ITEMS ASSEMBLY PARTS

DETERIORATED
ITEMS
The common Belief
• Every item is bought with some purpose hence should not be
thrown out

• What ever we have is a HOUSE/OFFICE not a godown


Decide on
• what should be thrown out
• Where to throw
• When to throw
• How to throw
• Who will decide to throw

Applying RED TAG concept


All items that have rare use or not required in a particular
department are tied with a red tag and kept in a separate area, so
the other departments could use these items if they required.
How to start SEIRI?
Let us compare!!

BEFORE AFTER
Let us compare!!

BEFORE AFTER
Let us compare!!

BEFORE AFTER
Let us compare!!

BEFORE AFTER
Let us compare!!
BEFORE AFTER
Let us compare!!
BEFORE AFTER

Area provided for the Project


cables and Electrical panel
room maintained in a good
environment.
Let us compare!!
BEFORE AFTER
2nd S- “Set In Order”
(Seiton - SYSTEMATIC ARRANGEMENT)

Arrange a place for everything. Everything in its place.

What do you understand by this ???


In a work place where SEITON is not Practiced

• Excess inventory

• High searching time

• Waste of human energy

• Hard to clean

• Non availability of items when required


SEITON Implies SYSTEMATIC ARRANGEMENT-
A Place for everything and place for everything in its place
[ Reserved seat method]

SEITON ensures that we don't waste our valuable time in


searching items
Criteria to help effective configuring

• One step rule:


Ideally nothing stored more than a step away.
Improve efficiency by eliminating time lost looking for items.
• 30 second rule:
Organize workplace to allow any tool, information or material to
be located and retrieved within 30 seconds. This includes
computer files!
• 45 degree rule:
Immediate work area layout to minimize twisting.
• Strike zone rule:
Store things above the knees and below the chest.
• The higher the pounds, the closer to the knuckles:
Locate heavy items to eliminate bending, stooping or
unnecessary arm movements during lifting.
Example of SEITON Practice in a Factory

• Properly laid gangways


• Proper identification of items
• Proper identification of racks
• Place markings
• Tiger stripes and fire extinguisher identification
• Push/pull markings
Let us compare!!

BEFORE AFTER
Let us compare!!
BEFORE AFTER
Let us compare!!
BEFORE AFTER
Let us compare!!
BEFORE AFTER
Before After
3rd S- “SHINE”
(SIESO)

What do you understand by this ???


In a work place where SEISO is not Practiced

• Poor morale and inefficient work.

• Puddles of oil and water cause slipping and injuries.

• Increased Break down time

• Increased rejection
The Three steps for SHINE/SEISO are

Major Cleaning Search for the sources

Individual Cleaning Workplace, equipment

‘Equipment 5S’,
Detailed Cleaning
special parts & tools
Maintaining a spotless workplace

• Floors
• Work areas
• Aisles
• Walls
• Pillars
• Ceilings
• Windows
• Rooms
• Electric Lights
To keep the workplace clean and inspect/maintain your equipment
• Clean everything
• Lubricate
• Inspect
• Tighten/ Retighten

Plant - 2
4th S –”STANDARDIZE”
(Sieketsu)

What do you understand by this ???


In a work place where SEIEIKETSU is not Practiced

• Conditions go back to their old undesirable levels.

• Work areas are dirty and cluttered.

• Tool storage sites become disorganized and time wasted

searching for tools.


Techniques For Standardization
1. Make Sort, Storing, and Shining a daily habit
2. Set the rules to make 5S part of everyone’s job
3. Assign responsibilities for Sorting, Storing, and Shining
4. Integrate Sort, Storing, and Shining into regular work activities
Let us compare!!
BEFORE AFTER

Zone – A1
5th S- “SUSTAIN”
(SHITSUKE)

What do you understand by this ???


In a work place where SHITSUKE is not Practiced

• Unneeded items begin piling up.

• Tools and jigs do not get returned to their designated places.

• No matter how dirty equipment becomes, nothing is done to clean it.

• Items are left in a hazardous orientation.

• All the first 4S will become waste, if it is not followed by self discipline

• Lack of shitsuke means not following standards. Not only 5-S but all ac
relating to safety and quality will also be affected
Shitsuke is like painting an iron part. Preventing us from going
back.
Until 5-S becomes a habit, the battle is not won
Effects of 5S

Safety Quality

Inventory Reduction of
Reduction Visualization of Waste & Loss
Problems

Shorter Better Facility


Lead Time Maintenance
Capability to Handle
Multiple Products
Let us compare!!

Before After
Let us compare!!

BEFORE 5S AFTER 5S
Let us compare!!

BEFORE 5S AFTER 5S
Let us compare!!

BEFORE 5S AFTER 5S
Let us compare!!

BEFORE AFTER
Let us compare!!
Let us compare!!
Let us compare!!
71
All the scrap materials are mixed All scrap materials are kept
and kept without identification. separately with identification.
Stock status not cleared. It is easy to know the stock
status and easy retrieval.
BEFORE – 5S AFTER – 5S

• No Gas line identification • Gas line identification done


• Difficult in Checking of Gas • Easy checking of Gas lines.
lines

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