5 s partex group

7/31/2019 5 S Partex Group

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APPLYING

5-S TECHNIQUES

FOR

IMPROVED WORK

ENVIRONMENT


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5-Ss are Basic inEstablishing Norms

for EffectivePerformance


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5-S is a KAIZENTechnique to Ensure

IncrementalImprovement


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ForWorkplace

Management


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Why Implement 5-S&

What are the real benefits ?a. Improves Productivity

b. Helps in proper maintenancec. Improves Quality

d. Improves Safetye. Reduces Costs

f. Detects Inconsistency in Workplace


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OTHER REASONS FOR IMPLEMENTING 5-S

Develops a KAIZEN mindset.

Build Teamwork

Establishes Discipline

Negligible Investment

Generates Enthusiasm

Implementation is Easy


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Some Points on 5-S If you cant do 5-S, you cant do other

work. The company thats doing badly is

doing the 5-S badly.

Moving from managing by results tomanaging by causes.

5-Ss are Crime Prevention.

5-Ss are management barometer.

If you can do 5-S, you can do anything.


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Where 5-S isApplicable?

Every Where


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DERIVED FROM THE FIRST LETTERS OF

EIRI

EITON

EISO

EIKETSUHITSUKE


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WHEN DO WE KNOW ABOUT THEM ?

5-Ss are there for a

very long time.


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WHAT ARE THE MEANING OF 5-Ss ?

EIRI

ORGANISE/ SORT

Distinguishing

between necessaryand unnecessary andgetting rid of what is

not needed.


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EITON

SYSTEMATISE/NEATNESS/LAYOUT

Establishing a neatlayout such that onecan always get as

much of what isneeded, whenneeded.


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EISO

CLEANING/ SHINE

Eliminate trash, filth

and foreign matter tohave a cleanerworkplace. Cleaning

as a form ofinspection.


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EIKETSU

STANDARDISATION &VISUALISATION

Keeping

everythingorganized neat

and clean.

Standards tomaintain.


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HITSUKE

DISCIPLINE/SUSTAIN

Doing the rightthing as a

routine matter.

G S


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General Scenario in Bangladesh

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G l S i i B l d h


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SEIRI


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SEIRI (Organise)Objective: To reduce or eliminate workplace clutter

thereby reducing space requirements, stock levels,

and reducing working capital. Thereby improving

productivity

Classify everything around you Separately store according to the classification

Discard all obsolete and unwanted things

Fix rules for disposal

Implement preventive 5S


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Understanding SEIRI (Reorganise)

ORGANISE/REORGANIZE THE WORKPLACE

There should be only items necessary toperform work at the workplace.

Dispose/remove all unnecessary items.

Ensure that unnecessary do not enter theworkplace.



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AS A PREVENTIVE MEASURE IDENTIFY HOW

UNNECESSARY ITEMS ENTERS TO THE WORKPLACE:

Organise procurement & stores.IDENTIFY THE EXCESS QUANTITIES

FOR THIS IT IS NECESSARY TO DECIDE WHAT IS

NECESSARY & UNNECESSARY IN A WORKPLACE:

So suggest them.

How to do SEIRI ?


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How to do SEIRI ?

1. Decide the scope of operation (what

workplaces, areas) and target to beachieved.

2. Get Ready.

3. Teach people to recognize what isunnecessary.

4. Quantity & access.

5. Perform management inspection andassessment.

Classification Stratification Management


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Classification - Stratification Management

Things we dont use

Things we dont use but

want to have on hand just

in case

Things we use on & off

Things we use infrequently

Things we use frequently

Discard

Keep as contingency items in

a separate store/record room

Store somewhere far away

Store in the workplace

Keep at the workplace


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Points to remember in classification

Items we do not use

Throw away

Donate

If difficult to get you may still keep

Sell and generate cash

Hazardous waste use appropriate disposal

means Confidential items - shred


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Three techniques to help Classification

The Red Tag Technique

The Yellow Tag Technique

Or use your 5 human senses Look

Listen

Feel

Smell

Taste


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Red Tag Technique

Using a suitable type of red colour disposal notice

1. Train persons in red tagging2. Apply the tags

APPLYING THE RED TAGS


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APPLYING THE RED TAGS

Decide on the standard for red tagging

Committee or Int. Audit

Make the red tags - paper, self adhesive tape, plastic

covers, round seals

Do the tagging during a selected period Mark details

Keep for exchange period

Get final approval for disposal or other action Dispose

Dont delay


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Red Tag Technique -Look at ...

Stocks

Facilities

Locations

Documents Machines

Fittings

Stationery Bank Accounts

Others


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You may discover

Defective items

Dead stock

Sleeping stock Excess materials

Excess spares


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If in doubt throw it out?

Or

Use the yellow Tag technique


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Yellow Tag technique

When you are not sure

On a fixed day label and mark date

If label items are used thereafter remove the

label.

Inspect after 6 months(or 1 year) - Which items

still have labels

If still not sure repeat inspection after one year.


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Advanced SEIRI - Habitual

Make rules for disposal by time or quantity

notices on notice boards, stocks, newspapers, used items,calendars, directories etc.

Reduce stocks

Mark min. and max. stock levels, fixed qty bins for forms,reduce bought out stocks, increase deliveries, reduceinventory by calculating stockminutes

Reduce W-I-P

Purely by implementing SEIRI


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Purely by implementing SEIRI

Many companies have Reduced space requirements

Given up plans for new storage buildings

Reduced the capital expenditure on cabinets etc.

Reduced overdrafts and borrowing

Generated Money in sales of discarded items

Made the factory look better

Made the office more pleasant

SEIRI


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SEIRI

Unnecessary Papers 12 Kg.

Necessary Papers 2.5 Kg.

BENEFITS OF SEIRI


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BENEFITS OF SEIRI

- Saves Floor Space

- Helps to Get Rid of Obsolete Item

- Gives a Clear idea of Material in Stock

- Prevent incidence of Unnecessary Buying

- Better Utilization of Existing Material

Understanding SEITON (Neatness)


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Keeping necessary things appropriately

such that - always available.

(A place for everything & everything inplace)

easily available.

All necessary things will have a fixed

determined space to keep known toeverybody.



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In keeping things consider classification

Ensure: Neat Workplace

Efficient Layout

Safe Keeping Eliminate search Efficient utilization of space

As if you can find things blindfolded.

SEITION


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Objectives are :

Reduce search, pick up and transport timeImprove Productivity of time

Reduce Personnel stressImprovequality of work life.

Improve quality of products and services

Prevention of defects. Improve safety


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Ensure:

Everything has a nameand location

Easy to keep

Easy to takeout

FIFO

Park like setting 30 Second retrieval

Understanding SEITON (Neatness)?


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Point to RememberJumble

Things are putevery whichway, whichmeans thatspace is used

inefficientlyand you cannotput as manythere as youshould be ableto.

Orderly

Things are putat right anglesand alongstraight lines.Space is used

most efficiently.Things are allfacing the sameway.

Every curvemeans a likelycollision andbreakage.Every curve is

dangerous.Every curvemeansslowingdown.

Curved

paths

Straight linesare safe lines.

Things movefaster andmoreefficiently.

Straightpaths



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Remember


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SEITON

should result inReduced or eliminated search time

No mix up

Workplace look neat and invitingNo stress

Can you find anything - a file, a tool, a document,

a particular letter in a file, the correct switch etc.in

just a couple of seconds?


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BENEFITS OF SEITON

Materials Easily Available

Materials Easily Retrievable Lesser Production

Downtime

Machine Breakdowns Handled Fast

Time Taken to Search Minimized


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SEISO (Clean)


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SEISO (Clean)

The objective of this step is to improve health of

machinery and human beings by a process ocleaning that makes checking easier.Create anobsession with cleanliness and to inculcate the

habit of cleaning by self.


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Develop a cleaning culture

Prepare a cleaning responsibility map

Prepare a cleaning responsibility schedule

Have a systematic approach

Have 3 or 5 minute cleaning

Understanding SEISO (Cleaning)

C


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Cleaning means inspection.

Remove dirt, dust, grime and foreign

materials from the work palace. Keep the work place & equipment in a ready

to use condition.

Keep work place clean and tidy.

Cleanliness is -- Primary Maintenance- Primary to Quality

Identify source of dirt and contain at thesource such that the workplace orequipment remain clean and useable.


Whil l i if d f


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While cleaning remove rectify defects.

Cleaning is a team work.

Cleaning is every bodies job.

Cleaning is a part of routine job.

Cleaning is a frame of mind: attitude

Create a pleasant environment.

Assign individual and collectiveresponsibility in cleaning.

Cl i ibili


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Cleaning responsibility maps

Entire premises divided into zones

Each zone to have a person responsible

including the CEO

Give clear directions on the standards expected

Even if a janitorial service is used their work must

be checked by the zone in charge

Cl i ibilit h d l


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Cleaning responsibility schedule

Divide responsibility for daily tasks to people

Display the schedule

May even give evaluation points

Cleaning in a Scientific Manner


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Cleaning in a Scientific Manner

What to clean?

When to clean?

In which order to clean?

Who is responsible?

How to clean?

What tools to use?

What materials to use?

Storage of cleaning tools

Cleaning is checking - use the 5 senses

The Original Condition policy


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It is true that machines begin deteriorating fromthe moment they are installed or unpacked.

But every effort must be made to bring the

piece of equipment back to original condition

every day.

Then lifetime will be prolonged and breakdownswill be less.

Cleaning is Checking


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Cleaning is Checking

Clean equipment will facilitate detection ofabnormalities.

Cleaning is not polishing etc to make the piece

of equipment more beautiful it is to look after

its health.

Corrode and paint - perfume without a bath.

GARBAGE BIN STRATEGY


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GARBAGE BIN STRATEGY

Have many garbage bins

Have many waste paper baskets

Locate at regular distances

Have separate bins for different items

Have lids

Teach people to use them

5 Minute Cleaning 5 Minute 5S


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5 Minute Cleaning 5 Minute 5S

Fixed time or ad-hoc time

Bell or alarm or music

Standardised procedure for checking

Everyone must participate

Rigidly applied even when on the phone or having

visitors



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1. Look for accumulated mucks, clogging rustleakage etc.

2. In case of lubricants is it up to the level ?Look for leakage, filter free clogging,damage, collection tray etc.

3. In case of a bolts: Is it properly tightened ?

Loose parts, vibration, sound, shockabsorber, getting heated etc.

Some Points



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5. Look at motors, condition of fans, fan-belt

coupling, joints, plugs, chains, pumps etc.6. Look at electrical items, panel conditions

safety lamp, bulb, switches etc.

4. Look into hydraulic tank, oil valves, filter,adjustment.



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7. 5-S Pledge

- I will not get things dirty.

- I will not spill.

- I will not scatter things around.

- I will clean things right away.

- I will rewrite things that have gotten erased.

- I will tape up things that have come down.


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SEIKETSU


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Standardize all three steps

Standardize procedures

Evaluate using checklist

Implement Good and

Bad stickers

(Standardization & Visual Management)

Understanding SEIKETSU(Standardization & Visual Management)


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( g )

Maintain strict control over Seiri, Seiton,

Seiso activities such that there is nodeviation.

Regularizing the 3-S activities so thatabnormalities show up.

Making deviations obvious with visualcontrol (Sensory alertness and control)

Anybody can spot an abnormality.

Visualization demonstrate alertness. Making the rules easy to follow.



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Tools and methods for visual control -

- displays to help people avoid makingoperating errors

- danger alerts- indications of where things should be put

- equipment designations

- cautions and operating reminders

- preventive maintenance displays

- instructions



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( g )

Standards on Right and Wrong-

- Make them easy to see from distance.- Put the displays on the things they are for.

- Make them so that anyone can tell what isright and what is wrong.

- Make them so that anybody can use themeasily and conveniently.

- Make them so that anybody can follow them

and make the necessary corrections easily.- Make them so that using them makes the

workplace brighter and more orderly.

The purpose of standardization is to make


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The purpose of standardization is to makesure that the entire organisation followsthe same procedures the same rules, thesame names, same sizes, shapes, andcolours etc..

Standardization may even be extended toother areas.



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(Sta da d at o & sua a age e t)

Visual Management -- levels.

- Precision Management level.

- Temperature Levels.

- Other relevant Levels.

- Okay Mark.

- Standard Inspection.



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- Lub. Oil.

- Inspection Levels.

- Zone Levels.

- Responsibility Levels.

- Position Mark.


Floor painting strategyW ki


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Working areas - green

Aisles - orange

Rest areas - blue

Warehouses - Gray

Types of lines and sizes

Avoid right angles

Door opening lines

Storage space lines

Traffic flow direction lines

Safety signs


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Safety signs

Dont do signs

Must do signs

Warning signs - Tiger patterns Safe way signs

Different colours

Prominently displayed

Fix item


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Fix item

Item identification

Shelf indication

Should be flexible

Position Marks


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Position Marks

Waste paper baskets

Garbage bins

Tables and chairs

Cupboards and other furniture

Inspection points

Wire Management


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g

Off the ground

Neat and straight

Colour coded

Storage of registers and files File index displayed


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File index displayed

Colour code

Oblique lines

Easy to see, easy to get and easy to return

Identification strips on registers and books

Homes for registers and books Index labels (A, B, C)

Tags for important pages

Owner

Review period

Summary pages

Next location



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Ensure

Safety

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5-m Gi c~e 5-m Gi ci


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5-m Gi c~e

5-m Gi ci


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5-m Gi c~e 5-m Gi ci


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SHITSUKE(TRAIN & DISCIPLINE TO

CULTIVATE SELF DISCIPLINE )


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CU S SC )

Make everyone committed to the programme

Motivate through competitions

Enforce discipline to inculcate self discipline Have a 5S Patrol Team

Rule observance campaigns

Games

Encourage preventive 5S

Understanding SHITSUKE( Discipline )

- Discipline as a way of cleaning


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- Discipline as a way of cleaninghabits.

- Doing the right thing as a matter of course.

- Following upon standardization & checklists.

- Practice until you can do it unfailingly.

- Rule Observance Campaign.

Important considerations in 5S

Silver bullet improvements or gradualist approach

Management must start 5S first If you can do


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Management must start 5S first. If you can do

5Ss you can do anything

5S is a barometer that tells you how well a

company is managed.

Implementation of 5S will indicate total

participation

5S will make the factory a sales tool.

5S to cleanse the heart

THE THREE TYPES OF WORKPLACES

3rd Class workplace


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3rd Class workplace

Where everyone messes the place and there is no one toclean up

2nd Class workplace

Where people mess up the place and office helpers,cleaners, janitorial services or servants clean up the place

1st Class workplace

Where everyone is disciplined and does not mess up andall participate in cleaning

3 PHASESOF


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IMPLEMENTATION

Active 5S Habitual 5S Preventive 5S

THE 5S CYCLE


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SHITSUKE

SEITONSEIRI

SEISOSEIKETSU


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