5 S Technique Production & Quality Management

Presented by SONI DARSHAN

14MMCM16

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Content

• Introduction

• Discovery of 5s

• The 5s principles

• Simple task to determine benefits of 5s system

• Daily life Examples of 5s

• 5s in Indian Industries

• 5S or 5D?

• Benefits of 5s

• Summary

• References

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INTRODUCTION[1]

5s is the name of workplace organization

method that uses a list of five japanese words:

• 1.seiri(sort)

• 2.seiton(set in order)

• 3.seiso(shine)

• 4.seiketsu(standardize)

• 5.shitsuke(sustain)

When Translated it into English , they all are

start with letter S.

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Cont.

The list describes how to organize a work space for

efficiency and effectiveness by identifying and storing the

item used, maintaining the area and items, and sustaining

the new order.

The decision making process usually comes from a

dialogue about standardization, which build

understanding among employees of how they should do

the work.

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Discovery of 5s [2] :

• Thirty years ago researchers started studying the secret

of success of Japanese manufacturing companies

• 5S turned out to be the most impressive "secret"

• The factories were so well organized that abnormal

situations were readily apparent

• Equipment were so clean and well maintained that any

problem such as a loose bolt or leaking oil could be easily

seen

• This passion of cleanliness and orderliness became a

hallmark of Japanese organizations

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The 5s principles[3]:

• 1. Sort - All unneeded tools, parts and supplies are

removed from the area

• 2. Set in Order - A place for everything and everything is

in its place

• 3. Shine - The area is cleaned as the work is performed

• 4. Standardize - Cleaning and identification methods are

consistently applied

• 5. Sustain - 5S is a habit and is continually improved

• Also - Work areas are safe and free of hazardous or

dangerous conditions

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The 5s’s:

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1.seiri(sorting/organizing)[3]

• Decide what you need

• Remove unnecessary clutter

• All tools, gauges, materials, classified and stored

• Remove items which are broken, unusable or only

occasionally used

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Cont.

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Before sort after sort

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Before sort after sort

2.Seiton (straighten/set in order)[3]:

• Organise layout of tools and equipment

• Designated locations

• Use tapes and labels

• Ensure everything is available

as it is needed and

at the “point of use”

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A place for everything and everything on its place."

Cont.

Workplace Checkpoints:-

• Positions of aisles and storage places clearly marked?

• Tools classified and stored by frequency of use?

• Pallets stacked correctly?

• Safety equipment easily accessible?

• Floors in good condition?

• Lights / Reflectors clean?

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3.Seiso (shine/sweep/scrub)[3]

• Create a spotless workplace

• Identify and eliminate causes of dirt and grime – remove

the need to clean

• Sweep, dust, polish and paint

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• Divide areas into zones

• Define responsibilities for cleaning

• Tools and equipment must be owned by an individual

• Focus on removing the need to clean

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Before shine after shine

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Before shine after shine

4.Seiketsu (standardize)[3]:

• Standardize clean-up activities by:

• Sustaining five-minute daily clean up habit

• Keeping a balance between personal

cleanliness and the cleanliness of the

environment / work place

• Avoiding littering. Learning to pick-up tiny pieces of waste around

• Regularly audit using checklists and measures of

housekeeping

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5.Shitsuke (sustain/self discipline)[3]:

• Instilling the ability of doing things

the way they are supposed to be done

• Becoming a role model by treating

your work place as your second home

• Influencing others to join in keeping

a well-maintained work place.

• Aiming for constant improvement

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A bad exampleof discipline

The Good, Bad and the Ugly

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First the Bad and the Ugly - Life Without 5S

The Good

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Simple task to determine benefit of 5s[4]:

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•In this photo you can see a rack

containing the forms and flyers common

in most HR departments

•Let us assume 600 employees need to go

to this rack from time to time, and say on

an average, everyone does this about three

times a year.

•Each person takes 15 minutes to look

through the rack. How much is the search-

hours ?

•With 5S’, it came down easily to a

minute or less per visit

•How much is the increase in productivity

?

How Does 5S Pay Off?

BEFORE 5S AFTER 5S

Visits 1800 Visits 1800

Time Spent Each Visit

15 Min Time Spent Each Visit 1 Min

Total Time for 600 Employees

450 Hrs.

Total Time for 600 Employees

30 Hrs

PRODUCTIVITY INCREASE (%)

93

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Daily Life Example of 5s[2]:

1. Hang hand towel nearer to sink (seiton)

2. Use CD organizer to organize CDs(seiton)

3. Use letter classifier to sorting the letters

(seiri and seiton)

4. Put instructions on the cover of home appliances like

washing m/c , mixture etc.(shitsuke)

Etc…………….

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5s in Indian industries[5]:

1. Metalfab high tech private ltd , Nagpur

2. BHEL-Bharat heavy electrical ltd.

3. L & T Larson and Turbo

4. Jyoti CNC

5. Waterman pump

6. Toyota and most of automobile company etc………..

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5S OR 5D…?

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• If 5S is not taken up seriously, then it leads to 5D.

• They are

• Delays,

• Defects,

• Dissatisfied customers,

• Declining profits and

• Demoralized employees.

Benefits[5]:

Improvements in:-

• Workforce morale

• Company image

• Health and Safety

• Machine maintenance

• Quality

• Productivity

• Leading to Increased Competitiveness

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Summary:

• 5s is one of the tool used for continuous improvement.

• 5-S is for you.

• Clean-up and organize your work area every day so that

each new day is easier and safer than the day before

• Share your input with your leaders so that the tools you

need will be available to you, increasing your efficiency.

• Volunteer to help with the 5S tours and 5S events.

• Take a good look around...Imagine zero waste/zero

confusion!

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References :

1.en.wikipedia.org/wiki/5s-methodology

2.The consultants guide to succesfully implementing 5s by Norm

Bain. Pp 44-46

3. www.toforceme.com/5s

4. Applying the kaizen method and 5s technique in the activity of

post-sale services in the knowledge based organization by

Mihail Aurel Titu; Constantin Oprean and Daniel Grecu.

5.Improvement of plant layout by using 5s technique – an

industrial case study by Dinesh B Shinde and Prashant N Shende

(This two international journals)

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THANK YOUFor listening me

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