AUTOMOTIVE SECTOR

5S

AUTOMOTIVE SECTOR

5S

What are the 5 Ss

Seiri
- Sorting
Seiton - Systematic Arrangement
Seiso
- Cleaning
Seiketsu - Standardization
Shitsuke - Training & Discipline

AUTOMOTIVE SECTOR

5S

AUTOMOTIVE SECTOR

5S

TO CLEARLY DIVIDE OBJECTS INTO TWO GROUPS

- THOSE ITEMS THAT ARE NECESSARY.
- AND THOSE ITEMS THAT ARE NOT NECESSARY.
TO GET RID OF THE UNNECESSARY
AND TO KEEP THE NECESSARY

AUTOMOTIVE SECTOR

5S

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

AUTOMOTIVE SECTOR

5S

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..
AUTOMOTIVE SECTOR

5S

Identifying unnecessary

2. Tools, Toolings, 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 itemsContd..
and things
nobody is likely to use
AUTOMOTIVE SECTOR

5S

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

5S

Identifying unnecessary
8.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Many unwanted, outdated, temporary files pile up

AUTOMOTIVE SECTOR

5S

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5S

AUTOMOTIVE SECTOR

5S

How to achieve Systematic Arrangeme

Decide where things belong

Decide how things should be put away

Obey the Put away rules

AUTOMOTIVE SECTOR

5S

How to achieve Systematic Arrangeme

Decide where things belong
- Standardize Nomenclature

- Determine an analytical method of stora

Decide how things should be put away

- Name & locations to everything. Label bo

and location
- Store material functionally
- Prevent mistakes with coding by shape
contd..
AUTOMOTIVE SECTOR

5S

How to achieve Systematic Arrangeme

Decide how things should be put away
- Follow first in first out rule

- If two identical items are to be located,

them separately, colour code them.

Obey the rules

- Put the things back to their location afte

their use

AUTOMOTIVE SECTOR

5S

AUTOMOTIVE SECTOR

5S

Clean workplace completely so that

there is no dust on the floor, machines
and Equipments

AUTOMOTIVE SECTOR

Activity

- Keep workplace spotlessly clean

- Inspection while cleaning
- Finding minor problems with cleaning
inspection

Success
Indicator

- Reduction in machine down time

- Reduction in no. of accidents

5S

While Cleaning up and getting rid of

dirt and unclear items potential
defects such as Abrasion, Damage,
Loose Parts, Deformities, Leaks,
Vibration, Abnormal Sound etc., are
revealed and hence Seiso is
inspection

AUTOMOTIVE SECTOR

5S

 Here cleaning means more than just keeping

things clean. Cleaning should be viewed as a
form of Visual Inspection
Preventive measures should be taken to tackle
problems of dust, grim, burrs, leakage etc.
Root cause of the problem should be identified
and it should be eliminated

AUTOMOTIVE SECTOR

5S

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

AUTOMOTIVE SECTOR

5S

Cleaning-Inspection points for mo

equipment
Tightening
Heat

AUTOMOTIVE SECTOR

Loose bolts, welding detachment,

loose parts, vibration or bumping
noise, friction

Oil tanks, motors, heater, axles, control

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

5S

Cleaning-Inspection points for mo

equipment
Breakage,
Cracks

AUTOMOTIVE SECTOR

Breakage, cracks, dent on sliding

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

5S

AUTOMOTIVE SECTOR

5S

Setting up Standards / Norms for

a Neat & Clean workplace and details
of how to maintain the Norms (Procedure)
Activity

- Innovative visual management

- Colour coding
- Early detection of problem and early action

Success - Increase in 5S indicator

Indicator

AUTOMOTIVE SECTOR

5S

AUTOMOTIVE SECTOR

5S

 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, deploy
visual management

AUTOMOTIVE SECTOR

5S

 It has been estimated by scientific

study that 60% of all human activities
starts with sight

5S is easy to do once.It is consistency

that is difficult. That is why Visual
Management is so important, so that
everybody will know that there is
some problem. Visual Managemen
AUTOMOTIVE SECTOR

5S

What visual control communicates ?

It grabs one or more of our senses in
order to

AUTOMOTIVE SECTOR

Alert us to an abnormality
Help us recover quickly
Promote adherence and prevention
Enable successful self management

5S

Some methods for visual communication

AUTOMOTIVE SECTOR

Colour coding
Use of Labels
Danger alerts
Indication where things should be put
Directional arrows/ marks
Transparent covers
Performance indicators

5S

Some everyday visual management

examples
Traffic signal
Zebra crossing
In car - Petrol indicator
- Speed indicator
Direction arrows
Electric danger sign etc.

AUTOMOTIVE SECTOR

5S

Some visual communication signs

AUTOMOTIVE SECTOR

5S

AUTOMOTIVE SECTOR

5S

We need everyone to maintain 5S

guidelines.
To maintain DISCIPLINE, we need
to practice and repeat until it
becomes a way of life.
Discipline is the Core of 5S
AUTOMOTIVE SECTOR

5S

Discipline means making a steady

habit of properly maintaining
correct procedure.
procedure
Time and effort involved in
establishing proper arrangement
and orderliness will be in vain if
we do not have discipline to
maintain it.
AUTOMOTIVE SECTOR

5S

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
AUTOMOTIVE SECTOR

5S

AUTOMOTIVE SECTOR

5S