Maintenance Execution: 5s Training
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MAINTENANCE EXECUTION 5S TRAINING 14th May 2018 1
2. Plan 3. Do
4. Check 5. Act
gend
1. Introduction to 5S
INTRODUCTION
5S A COMMON STEP IN LEAN DEPLOYMENTS IN WHICH CHANGE IS PUSHED SEIRI SEITON KAORO ISHIKAWA
SEISO
May 1950
SEIKETSU SHITSUKE 3
INTRODUCTION
st 1 SEIRI
S SORT
ELIMINATE UNNECESSARY ITEMS FROM THE WORKPLACE
4
st 1
5
S
SORT
INTRODUCTION
nd 2 SEITON
S SET IN ORDER
ARRANGE ITEMS SO THAT THEY ARE EASY TO USE, FIND AND PUT AWAY
6
nd 2
7
S
SET IN ORDER
nd 2
8
S
SET IN ORDER
INTRODUCTION
rd 3 SEISO
S SHINE
KEEP THE ITEM AND WORK AREA NEAT AND CLEAN
9
rd 3
10
S
SHINE
INTRODUCTION
th 4 SEIKETSU
S STANDARDIZE
CREATE A CONSISTENT APPROACH TO TASKS AND PROCEDURES
11
th 4
12
S
STANDARDIZE
INTRODUCTION
th 5 SHITSUKE
S SUSTAIN
MAKE A HABIT OF MAINTAINING THE CORRECT PROCEDURES
13
th 5
S
SUSTAIN THROUGH DISCIPLINE
14
SUSTAIN
LETS WATCH A MOVIE !!
15
PLAN
PREPARATION
HSE Provide training and education for everyone
1
2
Plan 5S action plan and launch
4
16
Set up 5S Zones
Determine 5S objectives, goals and implementation phases
3
DO
BEFORE YOU START
TAKE A PICTURE OF YOUR WORKSPACE
17
DO
1S - SORT (STEPS)
To eliminate unnecessary items from the workplace.
Look around you area and make list of all items prevailing to that area
Ask your team and yourself “Everything here is required or not”?
Sort out unnecessary and keep them in ”RED TAG AREA”
Decide what to be done with the RED TAG AREA items Make a schedule for 1s 18
DO
SORT (HOW WE APPROACH?) Decide what you need and frequency of the tools use
Remove unnecessary tools and materials Remove items which are broken, unusable/only occasionally used
Use RED TAG for disposal
19
DO
SORT
RED TAG AREA
BEFORE
20
Sample of RED TAG
AFTER
DO
2S - SET (STEPS)
To arrange items so that they are easy to use, find and put away. Understanding the frequency of usage of necessary item Give a place to all necessary items according step 1 Give a name code to very place and item Use separator line to maintain discipline Establish as many as visuals so that item can easily be tracked and placed Make sure no one can violet discipline 21
DO
SET (HOW WE APPROACH?)
SET means we arrange items so they are easy to use, and labeling them so they are easy to find and put away
It also means operating efficiency
22
DO
23
SET
DO
3S - SHINE (STEPS)
To keep the item and work area neat and clean.
Establish a cleaning schedule
Establish a cleaning tools
Establish a cleaning methods
Track abnormalities during cleaning
Strictly adhere the schedule 24
DO
SHINE (HOW WE APPROACH?) Create a spotless workplace
When you swap and shine an area, inspect the tools and materials condition Devote 5 min everyday for cleaning your work area Find out the source of contamination SHINE means we sweep floors, apply a fresh coat of paint etc and the we keep it that way.
25
Conduct root cause analysis to get the sources and solve it
DO
SHINE
Shine in Action
26
DO
4S - STANDARDIZE (STEPS)
To create a consistent approach to tasks and procedures.
Standardize 1S, 2S and 3S
Establish SOPs for 1S, 2S and 3S
Develop and establish 5S audits and frequency
27
DO
STANDARDIZE (VISUAL CONTROL) No need to ask, walk or think to get the status
Deviation should attract the eye at glance
VISUAL CONTROL refer to system of exposing deterioration or displaying the status just by making it visible 28
Should be unambiguous/universal
DO
STANDARDIZE
Example of Visual Control
29
DO
STANDARDIZE
Example of Visual Control
LABELS
STORAGE SPACE LINE
30
ITEM AND SHELF IDENTIFICATION
DO
5S - SUSTAIN (STEPS)
To make a habit of maintaining the correct procedures.
Ensure no one can violet Step 4
Create a 5S area map and assign owners for accountability
Schedule quarterly team meetings to review current state and identify progress Ensure everyone understands, obeys and practices the rules and procedures 31
DO
SUSTAIN (HOW WE APPROACH?)
Get everyone involved
Being critical of those not respecting the standards or not following the standard procedures
Not letting the external factor influence the application of 5S principles
32
CHECK
ASSESSMENT
Conduct Internal 5S Audit
Benchmark within the department with other organization
Ensure the established 5S procedures are followed through
33
ACT
CONTINUOS IMPROVEMENT
Develop 5S practices into HABIT
Compare actual goals with set goals
Reward and recognize efforts of staff
Revie Pan-Do-Check-Act- Cycle
34
5S ACTIVITY
35
FIND ALL NUMBER IN ORDER FROM 1 - 49
36
HOW MANY DID YOU FIND?
37
FIND ALL NUMBER IN ORDER FROM 1 - 49
38
WAS IT EASIER THIS TIME?
39
FIND ALL NUMBER IN ORDER FROM 1 - 49
40
WERE YOU ABLE TO FIND MORE?
41
FIND ALL NUMBER IN ORDER FROM 1 - 49
42
EASY RIGHT?
43
FIND 2 MISSING NUMBERS
44
DID YOU FIND MISSING NUMBER?
45
FIND 2 MISSING NUMBERS
46
DID YOU SEE HOW SIMPLE IT WAS?
47
5S POP QUIZ
48
Q1
What are the 5 phases of 5S?
A. Shine, Shut-Up, Sustain, Sort, Standardize B. Sustain, Sort, Standardize, Sushi mi, Shine C. Standardize, Sort, Sustain, Shine, Set-in-Order D. Sort, Sustain, Sushi, Shine, Standardize 49
E. Shine, Standardize, Sustain, Set-In-Order, Salami
Q1
What are the 5 phases of 5S?
A. Shine, Shut-Up, Sustain, Sort, Standardize B. Sustain, Sort, Standardize, Sushi mi, Shine C. Standardize, Sort, Sustain, Shine, Set-in-Order D. Sort, Sustain, Sushi, Shine, Standardize 50
E. Shine, Standardize, Sustain, Set-In-Order, Salami
Q2
Set-In-Order reduces what wastes? (Check all that apply)
A. Excess Motion B. Human Frustration C. Searching Waste
D. Productivity 51
E. Excess Inventory
Q2
Set-In-Order reduces what wastes? (Check all that apply) A. Excess Motion B. Human Frustration C. Searching Waste D. Productivity 52
E. Excess Inventory
Q3
Which phase of 5S are you in when you clean machines, windows, floors etc. A. Sort B. Set-In-Order C. Shine D. Standardize E. Sustain
53
Q3
Which phase of 5S are you in when you clean machines, windows, floors etc. A. Sort B. Set-In-Order C. Shine D. Standardize E. Sustain
54
Q4
Which one is NOT a benefit of Shine? A. Less production downtime B. Happier employees C. Improved quality D. Inventory reduction E. Customer satisfaction
55
Q4
Which one is NOT a benefit of Shine? A. Less production downtime B. Happier employees C. Improved quality D. Inventory reduction E. Customer satisfaction
56
Q5
Which is not a benefit of Sort?
A. Reduce the waste of searching B. Reduced set-up times C. Increased productivity D. Improved machine dependability E. Improved safety
57
Q5
Which is not a benefit of Sort? A. Reduce the waste of searching B. Reduced set-up times C. Increased productivity D. Improved machine dependability E. Improved safety
58
59
2. Plan 3. Do
4. Check 5. Act
gend
1. Introduction to 5S
INTRODUCTION
5S A COMMON STEP IN LEAN DEPLOYMENTS IN WHICH CHANGE IS PUSHED SEIRI SEITON KAORO ISHIKAWA
SEISO
May 1950
SEIKETSU SHITSUKE 3
INTRODUCTION
st 1 SEIRI
S SORT
ELIMINATE UNNECESSARY ITEMS FROM THE WORKPLACE
4
st 1
5
S
SORT
INTRODUCTION
nd 2 SEITON
S SET IN ORDER
ARRANGE ITEMS SO THAT THEY ARE EASY TO USE, FIND AND PUT AWAY
6
nd 2
7
S
SET IN ORDER
nd 2
8
S
SET IN ORDER
INTRODUCTION
rd 3 SEISO
S SHINE
KEEP THE ITEM AND WORK AREA NEAT AND CLEAN
9
rd 3
10
S
SHINE
INTRODUCTION
th 4 SEIKETSU
S STANDARDIZE
CREATE A CONSISTENT APPROACH TO TASKS AND PROCEDURES
11
th 4
12
S
STANDARDIZE
INTRODUCTION
th 5 SHITSUKE
S SUSTAIN
MAKE A HABIT OF MAINTAINING THE CORRECT PROCEDURES
13
th 5
S
SUSTAIN THROUGH DISCIPLINE
14
SUSTAIN
LETS WATCH A MOVIE !!
15
PLAN
PREPARATION
HSE Provide training and education for everyone
1
2
Plan 5S action plan and launch
4
16
Set up 5S Zones
Determine 5S objectives, goals and implementation phases
3
DO
BEFORE YOU START
TAKE A PICTURE OF YOUR WORKSPACE
17
DO
1S - SORT (STEPS)
To eliminate unnecessary items from the workplace.
Look around you area and make list of all items prevailing to that area
Ask your team and yourself “Everything here is required or not”?
Sort out unnecessary and keep them in ”RED TAG AREA”
Decide what to be done with the RED TAG AREA items Make a schedule for 1s 18
DO
SORT (HOW WE APPROACH?) Decide what you need and frequency of the tools use
Remove unnecessary tools and materials Remove items which are broken, unusable/only occasionally used
Use RED TAG for disposal
19
DO
SORT
RED TAG AREA
BEFORE
20
Sample of RED TAG
AFTER
DO
2S - SET (STEPS)
To arrange items so that they are easy to use, find and put away. Understanding the frequency of usage of necessary item Give a place to all necessary items according step 1 Give a name code to very place and item Use separator line to maintain discipline Establish as many as visuals so that item can easily be tracked and placed Make sure no one can violet discipline 21
DO
SET (HOW WE APPROACH?)
SET means we arrange items so they are easy to use, and labeling them so they are easy to find and put away
It also means operating efficiency
22
DO
23
SET
DO
3S - SHINE (STEPS)
To keep the item and work area neat and clean.
Establish a cleaning schedule
Establish a cleaning tools
Establish a cleaning methods
Track abnormalities during cleaning
Strictly adhere the schedule 24
DO
SHINE (HOW WE APPROACH?) Create a spotless workplace
When you swap and shine an area, inspect the tools and materials condition Devote 5 min everyday for cleaning your work area Find out the source of contamination SHINE means we sweep floors, apply a fresh coat of paint etc and the we keep it that way.
25
Conduct root cause analysis to get the sources and solve it
DO
SHINE
Shine in Action
26
DO
4S - STANDARDIZE (STEPS)
To create a consistent approach to tasks and procedures.
Standardize 1S, 2S and 3S
Establish SOPs for 1S, 2S and 3S
Develop and establish 5S audits and frequency
27
DO
STANDARDIZE (VISUAL CONTROL) No need to ask, walk or think to get the status
Deviation should attract the eye at glance
VISUAL CONTROL refer to system of exposing deterioration or displaying the status just by making it visible 28
Should be unambiguous/universal
DO
STANDARDIZE
Example of Visual Control
29
DO
STANDARDIZE
Example of Visual Control
LABELS
STORAGE SPACE LINE
30
ITEM AND SHELF IDENTIFICATION
DO
5S - SUSTAIN (STEPS)
To make a habit of maintaining the correct procedures.
Ensure no one can violet Step 4
Create a 5S area map and assign owners for accountability
Schedule quarterly team meetings to review current state and identify progress Ensure everyone understands, obeys and practices the rules and procedures 31
DO
SUSTAIN (HOW WE APPROACH?)
Get everyone involved
Being critical of those not respecting the standards or not following the standard procedures
Not letting the external factor influence the application of 5S principles
32
CHECK
ASSESSMENT
Conduct Internal 5S Audit
Benchmark within the department with other organization
Ensure the established 5S procedures are followed through
33
ACT
CONTINUOS IMPROVEMENT
Develop 5S practices into HABIT
Compare actual goals with set goals
Reward and recognize efforts of staff
Revie Pan-Do-Check-Act- Cycle
34
5S ACTIVITY
35
FIND ALL NUMBER IN ORDER FROM 1 - 49
36
HOW MANY DID YOU FIND?
37
FIND ALL NUMBER IN ORDER FROM 1 - 49
38
WAS IT EASIER THIS TIME?
39
FIND ALL NUMBER IN ORDER FROM 1 - 49
40
WERE YOU ABLE TO FIND MORE?
41
FIND ALL NUMBER IN ORDER FROM 1 - 49
42
EASY RIGHT?
43
FIND 2 MISSING NUMBERS
44
DID YOU FIND MISSING NUMBER?
45
FIND 2 MISSING NUMBERS
46
DID YOU SEE HOW SIMPLE IT WAS?
47
5S POP QUIZ
48
Q1
What are the 5 phases of 5S?
A. Shine, Shut-Up, Sustain, Sort, Standardize B. Sustain, Sort, Standardize, Sushi mi, Shine C. Standardize, Sort, Sustain, Shine, Set-in-Order D. Sort, Sustain, Sushi, Shine, Standardize 49
E. Shine, Standardize, Sustain, Set-In-Order, Salami
Q1
What are the 5 phases of 5S?
A. Shine, Shut-Up, Sustain, Sort, Standardize B. Sustain, Sort, Standardize, Sushi mi, Shine C. Standardize, Sort, Sustain, Shine, Set-in-Order D. Sort, Sustain, Sushi, Shine, Standardize 50
E. Shine, Standardize, Sustain, Set-In-Order, Salami
Q2
Set-In-Order reduces what wastes? (Check all that apply)
A. Excess Motion B. Human Frustration C. Searching Waste
D. Productivity 51
E. Excess Inventory
Q2
Set-In-Order reduces what wastes? (Check all that apply) A. Excess Motion B. Human Frustration C. Searching Waste D. Productivity 52
E. Excess Inventory
Q3
Which phase of 5S are you in when you clean machines, windows, floors etc. A. Sort B. Set-In-Order C. Shine D. Standardize E. Sustain
53
Q3
Which phase of 5S are you in when you clean machines, windows, floors etc. A. Sort B. Set-In-Order C. Shine D. Standardize E. Sustain
54
Q4
Which one is NOT a benefit of Shine? A. Less production downtime B. Happier employees C. Improved quality D. Inventory reduction E. Customer satisfaction
55
Q4
Which one is NOT a benefit of Shine? A. Less production downtime B. Happier employees C. Improved quality D. Inventory reduction E. Customer satisfaction
56
Q5
Which is not a benefit of Sort?
A. Reduce the waste of searching B. Reduced set-up times C. Increased productivity D. Improved machine dependability E. Improved safety
57
Q5
Which is not a benefit of Sort? A. Reduce the waste of searching B. Reduced set-up times C. Increased productivity D. Improved machine dependability E. Improved safety
58
59
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