Prepared By Haider Alam

PREPARED BY HAIDER ALAM

5S

5 S… SEIRI, SEITON, SEISOU, SEIKETSU, SHITSUKE

5S is the basis of all operations 5S is the basis of all production activities Manufacturing Division

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What is 5S ? Cleaning To create a safety working environment To produce good quality products To achieve maximum efficiency 2

５Ｓ 1. SEIRI 2. SEITON What do they actually 3. SEISOU mean ? 4. SEIKETSU 5. SHITSUKE 3

1. SEIRI Classify clearly the items into necessary and unnecessary items, then dispose of unnecessary items Do not leave SEIRI half done. All of the unnecessary items should be discarded.

Not N Not eces y r a s s sary e c e N

Not Necessary Not Necessary 4

How to implement “SEIRI” Step1:Classification – Classify into the necessary items and unnecessary items. Step2:Discard － “ Keep for any possibility to use”←Excuse Step3:Positioning － Decide “where to use” ”where to place” “how many” and “how to place”.

All of the non-frequent-use items are unnecessary 　 ・ No use more than 1 year －－－ ‐ Discard 　・ Use within 6 months to 1 year － ‐ Keep in far distance 　・ Use within 1 month to 6 months －－ ‐ Collect and Keep in one place of shop floor. 　・ Use in every week －－－－－－－－ Keep within work area 　・ Use in every day －－－－－－－－－ Easy picking 　　　　　　　　　　　　　　　　　 －－－－－ Easy return 　　　　　　　　　　　　　　　　　 －－－－－ Clear classification 　・ Use in every hour －－－－－ Place within the arm’s length5 　　　　－－ Items of right hand operation should be placed on the

2. SEITON Place necessary items at proper position for practical usage and clearly indicate the contents so that everyone can understand.

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Ｂ

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How to implement “SEITON” ・ Standardized location, Standardized quantity 　－ Easy picking, easy locating

・ Visually neat & clean and compact 　 － Condition of proper arrangement of passage, operation area, product storage site, jig & tools storage site and spare part storage site.

How to implement “standardized location and standardized quantity” ①Where to use 　 －－－－－→ Clarify the purpose of use, and place of use ②Where to keep 　－－－－－→ Place the items near to the place of use ③How many 　　－－－－－→ Decide the maximum and minimum quantity ④How to keep 　－－－－－→ Easy to place, Easy to pick (Use one-touch system) ⑤Indication of storage site －－－→ Color, box ⑥Visually understandable →Indication of items (Back Numbers), Indication of quantity ⑦Visually understand the period of stock→Visually understand the stock date, date of first-in and first-out” ⑧Fix responsible person for control →Clarification of responsible person 7

3. SEISOU

Keep cleaning up the working area, floor, equipments, jig&tools and part shelves and make them always clean. “SEISOU is to create the working area where special cleaning become unnecessary through daily check and measure for cause of dirt.”

In case of oil leakage on floor ･･･ Worker may slip and fall. It may cause an injury. It increases unnecessary cleaning (man-power and time are required) and wastes money.

In case cutting powders are clogging ･･･ Products are not fixed well on jig and it causes short stoppage. Powders come into the oil hole and it affects quality.

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4. SEIKETSU Keep 3S (Seiri / Seiton / Seisou) in good condition Frequent Seiri & Seiton are required. Seisou with few frequency is no use. Conduct Seiri, Seiton, Seisou periodically and keep working place neat and clean. That means, 3S must be implemented completely. 9

5. SHITSUKE Acquire the habit of doing what has been determined according to the set rules. Keep all the rules such as; Rule to secure safety Rule to assure quality etc.

Acquire the habit of keeping rules 10

How to implement “SHITSUKE” “SHITSUKE is to create standard to follow and to grow up the employees who can follow the standard and to make employees willing to follow ” The rules difficult to keep for yourself will not be able to be kept by your subordinates, either.

　　 Think about the reasons why rules are not kept and make rules which everyone can keep.

5S starts from SHITSUKE and finishes at SHITSUKE 11

Understanding of 5S Carry out 5S activity with full understanding. Know

Acquire the knowledge of 5S

Understand

Fully understand the meaning of 5S

To be able to carry out

Be able to carry out 5S activity

To be able to carry out as a habit

Get into the habit of taking 5S activity. (Repeatedly take 5S activities.) 12

Utilization of 5S

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Visible Control 13

I am taking one piece ！

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Seiri & Seiton are carried out

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What is missing now ？

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Visible Inventory Control

We can easily and clearly count the No. of items.

“Excess” or “Shortage” can be identified.

Inventory reduction has achieved. 17

Summary 1. SEIRI Classify clearly the items into necessary and unnecessary items, then dispose of unnecessary items

2. SEITON Place items at proper position for practical usage and clearly indicate the contents so that everyone can understand.

3. SEISOU Keep always cleaning up. And make the working area, floor, equipments, jig & tools and part shelves neat and clean.

4. SEIKETSU Keep 3S (Seiri / Seiton / Seisou) in good condition.

5. SHITSUKE Acquire the habit of doing what has been determined according to the set rules. 18

Points to effectively proceed 5S Point 1 Managerial class should take initiative as a model case. 　　 　 ① Show and verify the result to subordinates. 　 　　 ② Strengthen leadership ability of managerial class. 　　　　　 ③ Able to apply and continue for future development

Point 2 All of the employees should participate in activity 　　 ① Hold “5S time” for approx. 10 minutes every day 　　　 　 In case “5S time” is held during working time, it become one of their jobs and they become serious for 5S.

②5S activity should be the activity for all of the departments and sections such as deskwork staff, sales Div., manufacturing Div. and shop floor.

Point 3 Confirm the results 　　① Shoot videos of your own working area before the 5S implementation, and make a time-series video of the area according to the activity progress. 　　　　　　　　 (Fixed location observation)

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If 5S is carried out well, - Safety working place is created. - Good quality products are manufactured. - Maximum efficiency are achieved.

5S is the basis for all. 20

5S 　 Basic Education Text Code 3-004 　　　　 November 1, 2001

First Edition

October 1, 2002

Revision

June 1, 2005

Revision by NE-T 　 1

Issuing Department: Production Engineering Administration Department, Manufacturing Division, Suzuki Motor Corporation

This textbook is only for internal use. (All rights reserved.)

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