5S Presentation

Quality Improvements

INDIA

1950 1960 1970 1980

 1. 5S Principles

 Elimination of waste
 Every body is involved, Co-operative
effort
 Attack root cause
 Human being is not infalliable
 2. Objectives

 Improve housekeeping
 Make every individual
responsible for housekeeping
 Beautify by simple means
 Productivity improvement by
saving time, space etc.
 3. 5S’s

• Seiri - Sorting
• Seiton - Systematic arrangement
• Seiso - Cleaning
Inspection while cleaning
• Seiketsu - Standardization
• Shitsuke - Self Discipline
 5S
If we do not do 5S, we can’t do any
other work efficiently. They are features
which are common to all places and are the
indicators of
how well an organization is functioning.
 SEIRI = Sorting
Meaning Distinguish between necessary and unnecessary
items and eliminate the unnecessary items

Activity Establish a criteria for eliminating unwanted items

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

Success Area saved or percentage of space available

Indicator
 SEIRI = Sorting
Japanese Meaning : The Japanese meaning of
“Seiri” is to straighten and contain.
- Get rid of waste and put it in order according to
rules
OTHER JAPANESE MEANINGS -
farmland cultivation, Make an orderly system and
straighten
 What is unnecessary
Seiri = Sorting

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
 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
once in the last 2-6 months in your zone
AVERAGE
*Things used more than once Store it in central place
a month in your zone

HIGH *Things used once a week Store near the workplace

*Things used daily or hourly Store near the workplace
 Identifying
Seiri = Sorting
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..
 Identifying
Seiri = Sorting
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 items and things
nobody is likely to use
Contd..
 Identifying
Seiri = Sorting
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..
 Identifying
Seiri = Sorting
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
 Improvement
Seiri = Sorting
methods

1. Flow Process Chart (Procedural Analysis)

Drawing a process flow chart for the system
eg. How to make and use category wise grouping

2. Operational Analysis
Preparing the sequence of operations for system
eg. 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.
Dealing
Seiri = Sorting
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
Dealing
Seiri = Sorting
with papers

How to reduce papers on

your table ?

4 D Principle

DO
DELEGATE
DELAY
DUMP
 SEITION = Systematic Arrangement

Meaning To determine type of storage and layout that

will ensure easy accessibility for everyone .

Activity - Functional storage

- Creating place for everything and putting
everything in its place

Success - Time saved in searching

Indicator - Time saved in material handling
 SEITION = Systematic Arrangement

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
 SEITION = Systematic Arrangement

The main target areas for Seri-Seiton improvement are :

Tool-setting and preparation operations, line balancing and process planning,
parts supply to assembly line, peak time problems etc.

Improvement Methods
Kit Method / Assembly box method / Outside tool setting
Cassettisation / Parallel operations / Changes in assignment method
 Seiton = Systematic Arrangement

How to achieve Systematic Arrangement ?

• Decide where things belong

• Decide how things should be put away

• Obey the Put away rules

 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

contd..
 Seiton = Systematic Arrangement

How to achieve Systematic Arrangement ?

• Decide how things should be put away
- Follow 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
 Seiton = Systematic Arrangement

USE :

1 ) Signboards

2) Colour codes

3) Outline markings

4) Labels
Seiton = Systematic Arrangement

Functional

Storage
 Seiton = Systematic Arrangement

Usage • Store frequently used material

Frequency near the workplace and less
frequently at some distance

Weight & • Heavy material should be stored

Shape of the at lower levels/layers
Place directly on the material
Material
handling device for ease of
handling
Functional Storage
 Seiton = Systematic Arrangement

• Same category of material may be

Category
stored in one location.
Eg. Allen Screws, Oil Seals

Operation • All items required for an

Wise operation may be stored in one
location.
Eg. Allen key, spanner etc hand
tools required for setting m/c
Functional Storage
 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
• Stands and shelves
- Keep only required number of stands and shelves
- Standardize height, size
- Provide casters where necessary so that it can be
moved
 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
 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
 SEISO = Cleaning
Meaning Cleaning trash, filth, dust and other foreign
matter. Cleaning as a form of Inspection

Activity - Keep workplace spotlessly clean

- Inspection while cleaning
- Finding minor problems with cleaning inspection

Success - Reduction in machine down time

Indicator - Reduction in no. of accidents
 SEISO = Cleaning
Japanese 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 etc.
are revealed hence Seiso is Inspection
 Seiso = Cleaning

• 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
 Seiso = Cleaning

Various Minor Defects

= Trash = Dirt =Knocking
= Loose parts = Leaks =Scattering
=Skips =Curvature =Abrasion
=Rust =Scratches =Eccentricity
=Lurching =Abnormal =Vibration
Movements
=Abnormal =Heat =Abnormal
Sounds smells
=Faded colour =Hisses
 Seiso = Cleaning

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

 Seiso = Cleaning

Cleaning-Inspection 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.
 Seiso = Cleaning

Cleaning-Inspection 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.
 Seiso = Cleaning

Cleaning-Inspection 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.
 Seiso = Cleaning

Function wise Cleaning check list of

equipment
Compressed Air lines, air valves,
Pneumatics connections, meters, filters,
reservoirs etc.

Hydraulic oil tank, oil valves,

Hydraulics filters, pumps, hoses, gauges,
cylinders etc.
 Seiso = Cleaning

Function wise Cleaning check list of

equipment

Mech & Motor fan, fan belt, couplings,

Joints, pulleys, chains, pump
Power Train
bearings etc.

Control panel, lamps, light, switch,

Electrical sensors, wiring, ducts, fuses etc.
 Seiso = Cleaning

Function wise Cleaning check list of

equipment

Tools, fixtures, gauges, dies,

Toolings measuring instruments, etc.

Equipment Furnaces, rollers, chutes,

Specific CNC machines, etc.
 SEIKETSU = Standardization
Meaning Setting up standards / Norms for a neat, clean,
workplace and details of how to maintain the norm
(Procedure)

Activity - Innovative visual management

- Colour coding
- Early detection of problem and early action

Success Increase in 5S indicator

Indicator
 SEIKETSU = Standardization
Japanese Meaning :
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.
 SEIKETSU = Standardization
Tools used for analysis :
MTTR
MTBF
OEE
 Seiketsu = Standardization

• 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
 Seiketsu = Standardization

• 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 Management
 Seiketsu = Standardization

What visual control communicates ?

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
 Seiketsu = Standardization

Some methods for visual communication

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

Some methods for visual communication

Labels
 Precision management labels
 Inspection labels
 Temperature labels
 Responsibility labels
 Seiketsu = Standardization

Points to remember in making visual c

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
 Seiketsu = Standardization

Some everyday visual management

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

Some visual communication signs

 SHITSUKE = Self Discipline

Meaning Every one sticks to the rule and makes it a habit

Activity - Participation of everyone in developing good

habits
- Regular audits and aiming for higher level

Success High employee morale

Indicator Involvement of all people
 SHITSUKE = Self Discipline

Japanese Meaning :
Dictionary meaning is
“learning of the manners”
“having manners, dressing neatly” OR
“training children for good customs”
 SHITSUKE = Self Discipline

Activities :
5S Committee
5S Training
5S Competition / evaluation
5S Month
Posters , Literature etc.
 Shitsuke = Self Discipline

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

 Shitsuke = Self Discipline

Discipline means making a steady

habit of properly maintaining
correct procedure.

Time and effort involved in

establishing proper arrangement
and orderliness will be in vain if
we do not have discipline to
maintain it.
 Shitsuke = Self Discipline
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
 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
 Implementation Target

• TOTAL FACTORY

• 200 people/month to be trained

• Every 3 month 25% area will be
covered