5S Role in Achieving Quality

A STRATEGY FOR PERFORMANCE EXCELLENCE

5S

5S

What is 5S ? An essential step required for Waste

Elimination

An integral step in Kaizen A required element to achieve Lean-site

Manufacturing.

Systematic Organization

“Seiri”

Orderliness

“Seiton”

Cleanliness

“Seiso”

Cleanup

“Seiketsu”Standardization/Perseverance

“Shitsuke”

Cleanup“Seiketsu”

The Five Elements of 5SSelf-Discipline/Control-Ensuring that Systematic Organization, Visual Placement & Cleanliness are maintained.

Systematic Systematic Organization- Identifying what items are required and which are not.

Sorting Visual Placement- Items should be easily retrievable, easy to get, and visual-easy to see.

Scrubbing Clean-Keep the area free from debris, dirt, oil, items not needed.

Standardizing Control- Maintain and continually improve the previous improvements.

5S Improvement in Performance

•To eliminate the wastes that result from“uncontrolled” processes.• To gain control on equipment, material & inventory placement and position.• Apply Control Techniques to Eliminate Erosion of Improvements.• Standardize Improvements for Maintenance of Critical Process Parameters.

Why 5S

The Nine types of wastes.

Overproduction Delays (waiting time) Transportation Process Inventories Motions Defective products Untapped Resources Mis-used Resources

5 S Element Waste/ Improvement Item Deliverable

SystematicOrganization

Elimination of finding.Reduction of part selection errors.

Reduced CostsImproved QualityIncreased Product Options

Sorting-VisualPlacement

Elimination of finding.Elimination of nonconformances.Elimination of motion.Reduction of part selection errors.

Reduced CostsIncreased SafetyImproved QualityIncreased Product Options.

Scrubbing Clean Increased safety.Preventive maintenance.Increased equipment knowledge.

Increased SafetyImproved Quality

StandardizationControl

Increased equipment life.Higher morale.Clean environment.Increased visibility of nonconformances.

Improved QualityConsistent DeliveryImproved Safety

Elimination of Waste

Systematic

Organization

CleanlinessVisual Placement

StandardizationProgressive

Enhancements

Step 2

Develop Specific

Implementation Plan

Step 3

Develop Communication

Plan

Step 4

Develop 5 S Training PlanStep 5

Implement 5 S

Step 6

Verification of Effectiveness

Step 1

Establish 5 S

Implementation Team

5S Implementation Plan

Key to successful Implementation of 5S

Some evidence of standardized work areas

•Clear, shiny aisle ways

•Color coded areas

•Slogans, banners

•No work-in-process ( WIP )

•One-Piece Flow

•Standardized Work Sheets

Visual Color System Implementation

• Develop a map identifying the “access ways”(aisles, entrances, walkways etc.) and the “action” areas.

• Perform any necessary realignment of walkways, isles, entrances.

• Assign an address to each of the major action areas.

• Mark off the Walkways, Aisles & entrances from the action areas.

• Apply flow-direction arrows to aisles & walkways

• Perform any necessary realignment of action areas.

• Mark-off the inventory locations

• Mark-off equipment/machine locations

• Mark-off storage locations( Cabinets,shelves,tables)

• Color-code the floors and respective action areas

Cleanliness involves cleaning every aspect of the Organization and the removal of dirt,

dust,oil, scraps on the floor, & garbage.

Key Deliverables

Increased Safety

Increased Efficiency

5S Action Items

Table of Contents

Section 1 Development of 5S “To Do” Plan: Establishment of the 5S team focused onthe development, training, and implementation of the company’s 5S program.Deliverable includes action plan and associated tasks with the 5Simplementation. ………………………………………………………………………… 4

Section 2 Waste Identification Map: Identification of the 9 wastes associated withproduction of products and services. A detailed map of each major work area isdeveloped describing the major types of wastes in each area. These wastes arethe improvement opportunities that exist prior to5S………………………………...

The overall wastes is calculated for all the work areas and identified on the 9Waste Radar Chart

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Section 3 5S Action sheet: Establishing baseline key performance metrics in terms ofkey deliverables, photographs, and current conditions of the “before” 5Simplementation phase. Deliverable includes the 5S actionsheet………………….

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Red Tag Strategy: The utilization of “Red Tags” to visually identify items whichare not needed or used infrequently………………………………………………….. 14

Section 5 Visual Color Sheets: Utilization of colors to identify specific work actions,inventory locations, access areas within the work environment. Initializationbegins with development of Visual ColorSheets…………………………………….

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5S Action Items

Section 6 Visual Sign Sheets: Utilization of signs to identify machine, equipment, tooling,inventory, safety, hazard and work center locations. Sample SignSheets……….

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Section 7 Standard Cleaning Work Sheet: A cleaning matrix identifying the work arearesponsibilities, supplies, and schedules for cleaning. …………………………….. 23

Section 8 Cleaning “To Do List”: A action list identifying specific cleaning tasks for eachwork area identified on the Standard Cleaning Work Sheet……………………….. 27

Section 9 5S Status Report: A report identifying implementation effectiveness of each 5Ssteps applied. A variable metric ranging from 0-5 is established for each stepimplemented…………………………………………………………………………….. 30

Section 10 Waste Identification Map: Identification of the 9 wastes associated withproduction of products and services. A detailed map of each major work area isdeveloped describing the major types of wastes in each area. These wastes arethe improvement opportunities that exist prior to 5S……………………………

9 Wastes Radar Chart: After the completion of 5S, the results of the waste reductionis recorded, charted and compared to the initial 9 Waste Radar Chart.

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