An Introduction To 5s Activities

Seiri Seiton Seiso Seiketsu Shitsuke

Quality Improvements

N A P JA

U.S.A INDIA 1950

1960

1970

1980

1. 5S Principles  Elimination of waste

 Every body is involved, Co-operative effort  Attack root cause  Human being is fallible

2. Objectives  Improve housekeeping  Make every individual responsible for housekeeping  Beautify by simple means  Productivity improvement by saving time, space etc.

3. 5 S’ s • Seiri • Seiton • Seiso

- Sorting - Systematic arrangement - 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.

COMMON MIND SETS… Its an additional burden. Too busy to do 5S activities. Why clean it? It will get dirty again We cannot change the existing setup. More work pressure – No time for these things 5S means cleaning up the desk

SEIRI = Sorting – Just in Case to “Just-in-Time”

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 – Fight with habits

SEIRI = Sorting 3 Categories

√ - Item Required X – Item Not Required ?–

Undecided Move to Red Tag Holding Area

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. Item is needed but once in a blue-moon 4. Contingency Parts Critically decide the quantity of contingency parts to be retained and criteria for such parts

Organization Frequency of use

A E VE R A

G

LOW

HIGH

Storage Method

*Things you have not used Throw them out 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 *Things used more than once Store it in central place a month in your zone *Things used once a week Store near the workplace *Things used daily or hourly Store near the workplace

Seiri = Sorting

Identifying unnecessary

1. Parts & Work in Process (WIP) • Things fallen back behind the machine or rolled under it • Broken / some 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..

Seiri = Sorting

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 items and things nobody is likely to use Contd..

Seiri = Sorting

Identifying unnecessary

4. Shelves and Lockers • Shelves and lockers tends to collect things that nobody ever uses, like surplus, broken items, used tea-cups etc. 5. Passages and Corners •WIP material waiting for decision or dispatch • 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..

Seiri = Sorting

Identifying unnecessary

8.Floor, Pits, Partitions • Defective parts • Protection caps, shoe covers • Packing material, stickers, barcodes, cut-leads • Hardware items, small items, runners, plastic granules • Even tools, tooling Items dropped on the floor are never picked 9.Computer Hard Disk • Many unwanted, outdated, temporary files pile up •Old dated mails still remaining in inbox and sent items •Deleted mails not being purged when closed •Recycle bin not emptied

RED TAG

GIC

Seiri = Sorting

TAGGING

TAG No ______________

Date _________

ITEM NAME________________

QTY ______

Tag Created By: _________________________________ Reason: ________________________________________ _______________________________________________ _______________________________________________ Decision Date: ___________ To Scrap

Decision By: __________

To Reuse after Salvage

To Dispose

Seiri = Sorting

Improvement 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.

PLANT: AREA: No.

1 - S CHECKLIST - SHOPFLOOR DATE: PERSON RESPONSIBLE: PARAMETERS EXCE. GOOD AVG. BAD POOR POINTS 5 4 3 2 1

1 Is there any UNWANTED item present in area 2 Is there any item more than required 3 Is there any item on different location 4 Is there proper Red Tag Area identified 5 Is the list of all items in Red Tag Area available 6 Is there any classification done for Wanted items 7 Is there any item not used for more than a year 8 Is there criteria present to eliminate unnecessary items 9 Is there any unwanted dirt/dust present 10 Is there any leakage present (Air, Water, Oil or Material) 11 Is there any defective item present or Unsafe item in the area 12 Is there any spilled item on the floor 13 Are all Equipments, Jigs & Machines working OK 14 Is there minimum 20 % storage free space available 15 Are People working in the area aware about 1 - S OVERALL SCORE REMARKS:

NOTE: MINIMUM 75 % REQUIRED FOR NEXT STEP AUDIT

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

Seiri = Sorting

Dealing 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 (30 sec to locate an item) Indicator - Time saved in material handling

SEITION = Systematic Arrangement In short, SEITION means PEEP

Place for Everything & Everything in its place

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

ow to achieve Systematic Arrangement ? ecide where things belong

Standardize Nomenclature Determine an analytical method of storage

ecide how things should be put away

Name & locations to everything. Label both ite and location - Store material functionally - Prevent mistakes with coding by shapes & co contd..

Seiton = Systematic Arrangement

w to achieve Systematic Arrangement ? cide how things should be put away

ollow first in first out rule If two identical items are to be located, then s them separately, color code them.

bey the rules

ut the things back to their location after their use

Seiton = Systematic Arrangement USE : 1 ) Signboards 2) Color codes 3) Outline markings 4) Labels

Seiton = Systematic Arrangement

Functional

Storage

Seiton = Systematic Arrangement

• Store frequently used Usage Frequencymaterial

near the workplace and less frequently at some material should be stored Weight &• Heavy distance at lower levels/layers Shape of the Place directly on the material Material handling device for ease of handling

Functional Storage

Seiton = Systematic Arrangement

Category

• Same category of

material may be stored in one location. Eg. Fasteners, Seals , resistors • All items required for an Operation operation may be stored in one Wise location. Eg. Allen key, spanner etc hand tools required for setting m

Functional Storage

Seiton = Systematic Arrangement

tlining and Placement Marks

Mark boundaries of dept., aisles, Machines Follow straight line, right angle rule Nothing shall be kept outside the boundaries

ands and shelves

eep only required number of stands and shelv Standardize height, size Provide casters where necessary so that it can moved

Seiton = Systematic Arrangement

res and Ducts

olor code When there are multiple connections - bundle wires, label them and make sure that they are straight line /right angle and firmly anchored

achine-tools & Tools

ut the tools in the order you need them Location of the tool should be such that it can put away with one hand Try to eliminate some hand tools by permanen attaching it to the bolt head

Seiton = Systematic Arrangement

des, Dies, Other important consumables

tore them in the protected place Maintain these things regularly by applying ru preventive, oiling etc.

P- Work In Process

esignate 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 not mislabeled

Seiton = Systematic Arrangement

s & Lubricants

Reduce number of oils used (Standardize) Color code for oil Safety aspects - fire prevention, pollution, lea spillage

trumentation & Measuring Devices

abel 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 Indicator

- Reduction in machine down time - Reduction in no. of accidents

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 color =Hisses - Cracks

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.

Oils

No oil, Low oil, leakage, filter clogging, dirty oil, dirty or bent oil lines, clogged drainage, oil spillage, worn& torn ports etc.

Seiso = Cleaning

Cleaning-Inspection points for most equipment Tightening Heat

Loose bolts, welding detachment, loose parts, vibration or bumping noise, friction

Oil tanks, motors, heater, axles, control panels, washing/ cleaning water, bearing, wiring etc.

Seiso = Cleaning

Cleaning-Inspection points for most equipment Breakage, Cracks

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.

Seiso = Cleaning

Function wise Cleaning check list of equipment Pneumatics

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

Hydraulics

Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc.

Seiso = Cleaning

Function wise Cleaning check list of equipment Mech & Power Train Electrical

Motor fan, fan belt, couplings, Joints, pulleys, chains, pump bearings etc. Control panel, lamps, light, switch, sensors, wiring, ducts, fuses etc.

Seiso = Cleaning

Function wise Cleaning check list of equipment Toolings Equipment Specific

Tools, fixtures, gauges, dies, measuring instruments, etc. Furnaces, rollers, chutes, 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 - Color coding - Early detection of problem and early action

Success Indicator

Increase in 5S indicator

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 ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒

Color 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 photos

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 ♦ Toilet

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 Indicator

High employee morale Involvement of all people

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. 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

Machine building Bay

Heat Treatment Area

Heat Treatment Area

Machine Shop

End of the presentation & Beginning of 5S activities….