5s module

5STRAINING

MODULE STRUCTURESession Duration

1. Session 01 - Importance of Target and Our Vision 15 Minutes

2. Session 02 - An Over-view of 5S 15 Minutes

3. Session 03 - 1S - SEIRI 30 Minutes

4. Session 04 - Genba Exercise (1S Master list) 15 Minutes

5. Session 05 - Genba Exercise (1S Master list-Distinguish) 15 Minutes

6. Session 06 - 2S - SEITON (Examples) 30 Minutes

7. Session 07 - 2S - Genba Exercise 30 Minutes

8. Session 08 - 3S - SEISO 15 Minutes

9. Session 09 - 3S - Check sheet 15 Minutes

10. Session 10 - 4S - SEIKETSU 15 Minutes

11. Session 11 - 5S - SHITSHUKE 15 Minutes

12. Session 12 – SUMMARY 5S 30 Minutes

MODULE DURATION : 04 HOURS

SESSION 1Importance of Target and Our Vision

DURATION : 15 MINUTES

Nothing is impossible……………..

IF YOU WORK WITHOUT TARGETS, IT WILL BE LIKE…

WITHOUT A LIGHT HOUSE

WITHOUT WICKETS

CRICKET

SHIP

IF WE DON’T FIX TARGET, WE DON’T KNOW WHERE WE HAVE TO GO

MOVING TOWARDS

CRICKET

WITH

WICKETS

SHIP LIGHT HOUSE

IF YOU WORK WITH TARGETS, IT WILL BE LIKE…

FIX THE TARGETFIX THE TARGET

BE CLEAR ABOUT YOUR TARGET

EVERYTIME WE FIX HIGHER TARGET, WE WILL STRETCH OURSELF AND

PERFORM BETTER

TARGET

TARGET STOPS US FROM DOING UNPRODUCTIVE JOBS

TARGET PREPARES US TO GO AHEAD TO REACH THE SET GOAL

TARGET GIVES US A GREEN SIGNAL IF WE ARE ON THE RIGHT PATH

What is important to construct a strong building ?

Strong, Good

Foundation

is the basic criteria to construct

a rigid structure !

What is our Company’s vision ?

Building Infrastructure

Globally

Is the foundation

What is 5S ?What is 5S ?

NEXT SESSION

SESSION 2An Over-view of 5S

DURATION : 15 MINUTES

1S-SEIRI 2S-SEITON

3S-SEISO4S-SEIKETSU

5S-SHITSHUKE

ETPL

5S5S

Visual Factory • “Ability to understand the status of a production area

in 5 minutes or less by simple observation without use of computers or speaking to anyone.”

Objectives of 5S

3. PRODUCTIVE WORK PLACE

1. VISUAL WORKPLACE

2. SAFE WORKPLACE

4. STANDARDISED WORK PLACE

5. PLEASANT WORK PLACE

What we do on BHOGI festival ?

•Segregate unwanted things.•Keep it away.•Burn / throw out.

Why ?

But what about our working area ?

Abnormalities

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

In the following pictures, identify some of the” Abnormalities”

Tomo Sugiyama’s wisdom

People leave trash. People tolerate it. No one step to

pick up.

Tomo Sugiyama’s wisdom

People leave trash , some do not tolerate it , pick it up

Tomo Sugiyama’s wisdom

People do not leave trash , people do not tolerate it ,

Everyone picks it

SESSION 31S - SEIRI

DURATION : 30 MINUTES

How to get first level?

MR.DOUBT

Key 1: Seiri (Sorting)

Distinguish Between What Is Needed And Is Not Needed

Distinguish Between What Is Needed And Is Not Needed

Before starting 1S,

Let me tell you a story…

I am the goddess who give you all the below things. Who am I ?

I am the goddess who give you all the below things. Who am I ?

I am the goddess of

good fortune & wealth .

I am the goddess who gives you all the below things. Who am I ?

I am the goddess who gives you all the below things. Who am I ?

I am the goddess who gives you all the below things. Who am I ?

I am the goddess of poverty &

odium

Once upon a time…..

Both the goddess had a competition of who is

beautiful among them and they went to Narada for

judgment

Narada, tell me who is beautiful

among us ?

You both are You both are

equally beautiful…..equally beautiful…..

Lakshmi, you are beautiful Lakshmi, you are beautiful

when you when you ENTERENTER & Moodevi, & Moodevi,

you are beautiful when you you are beautiful when you

EXITEXIT

Good things are beautiful

when they enter and bad things when they exit

Good things are beautiful

when they enter and bad things when they exit

Theme

Now what do you want ?

Good things to enter

Or

Bad things to enter

To receive Lakshmi to our house/ factory / anywhere , what should we do ?

HOW TO DO 1S?

NEXT SESSION

SESSION 4GENBA EXERCISE (1S MASTER LIST)

DURATION : 15 MINUTES

MR.DOUBT

HOW TO DO 1S?

GIVE ONE- ONE IDEA

ALWAYS KEEP IN MIND-

DO WHAT YOU DOCUMENT,

DOCUMENT WHAT YOU DO

AGAIN GIVE ONE ONE IDEA- HOW CAN 1S BE DONE WITH

DOCUMENTS

NEXT SESSIONGENBA EXERCISE

(1S MASTER LIST – DISTINGUISH)

SESSION 5GENBA EXERCISE

(1S MASTER LIST-DISTINGUISH)

DURATION : 15 MINUTES

Read 1S List…One by One

Now…. Let’s go to Shop floor… & Distinguish Necessary &

Unnecessary Items…

TIME LIMIT : 10 MINUTES

Share the Learning…One by One

Height of housekeeping Height of housekeeping

MR.DOUBT

Where to keep the unnecessary items?

• • Temporary storageTemporary storage

• • Local holding areaLocal holding area

• • High VisibilityHigh Visibility

• • Holding area managerHolding area manager

• • Timely clearingTimely clearing

Red Tag Holding Area

WHAT IS 2S?

NEXT SESSION

SESSION 62S - SEITON

DURATION : 30 MINUTES

WHAT IS 2S?

Key 2: Seiton (Systematic Arrangement)

For Storing any items, following seven points For Storing any items, following seven points should be Considered :should be Considered :

1. Search Free

2. Count Free

3. Air Free

4. Climb Free

5. Bend Free

6. First in First Out

7. Heavy things on Lower Shelves

8. Store should be lighted & ventilated properly.

4 Good Signs of 2S

1. LOCATION : Outline, Arrows, Separators

2. IDENTITY : Description - “What is it?”

3. QUANTITY : How many should be here

4. INSTRUCTION : What do you want me to do?

4 Good Signs of 2S

1. LOCATION : Outline, Arrows, Separators

2. IDENTITY : Description - “What is it?”

3. QUANTITY : How many should be here

4. INSTRUCTION : What do you want me to do?

MR.DOUBT

STILL I AM NOT CLEAR ABOUT 2S?

Bolts

4 Pallets

1000x43 - SPECIFY QUANTITY

Bolts

1 - PROVIDE LOCATION

2 - PROVIDE IDENTIFICATION / NAME BOARD

3 - PROVIDE INSTRUCTIONS

4 Pallets

1000x4

Bolts

Delivery Time: 9.00 AMDaily

Let us see some Examples…

Team Member Area Information Board

1st Shift 2nd Shift

All Shift Communication Board

Production Graphs

Team MemberTraining Log

Sheets

Run TimeLog Sheet

Moulder SetupSheets

MaintenanceRequest Forms

Maintenance Repair Log

(Team MemberMaintained)

(Team MemberMaintained)

Tool and WIP BoardTo Be

Ordered

In Process

Next Run

Spec Card

Maintenance Log&

Maintenance Request Forms

Clean-up / WIP BoardTo be Ordered

In Process

Next Run

PreventativeMaintenance

Schedule Calendar

Organize & Demand the Maintenance of Tools

Everything has a Dedicated Home

Seiton workplace example..

VCS provided for component storage

Inserts / tools stored in bins with VCS

Seiton workplace example..

5S

Point of use tools in Mill Room What is needed, in reach, ready for use

Now…. Let’s go to Shop floor… &

Identify Location for Necessary Items…

TIME LIMIT : 20 MINUTES

Share the Learning…One by One

WHAT NEXT?

NEXT SESSION

3S

SESSION 83S – SEISO

DURATION : 15 MINUTES

Key 3: Seiso (Cleanliness)

“Cleaning Is Inspection"

• Eliminating all forms of dirt

• Finding ways to keep the workplace clean

• Adopting cleaning as a form of inspection

• Making cleaning part of everyday work

What is the army man standing in front of before going for war ?

Am I smart

Shine Concept…

• Clean to Inspect

• Inspect to Detect

• Detect to Correct

• Correct to Perfect

WHAT NEXT?

NEXT SESSION

3S – CHECKSHEET

SESSION 93S – CHECK SHEET

DURATION : 15 MINUTES

WHAT NEXT?

NEXT SESSION

4S

SESSION 104S – SEIKETSU

DURATION : 15 MINUTES

Maintain and monitor the first three KeysMaintain and monitor the first three Keys

Key 4: Seiketsu (Standardize)

• • CheckCheck• • StandardizeStandardize• • MaintainMaintain• • MonitorMonitor• • ImproveImprove

SESSION 115S – SHITSHUKE

DURATION : 15 MINUTES

Key 5: Shitshuke (Self-Discipline)

“SAY WHAT WE DODO WHAT WE SAY"

Shitshuke (Self-Discipline)

• Correct procedures are habitual

• Workers are properly trained

• Everyone has adopted Visual Factory

• The workplace is well

ordered according to agreed

upon procedures

• Managers are committed to

the 5 Keys as a way of doing

business.

PROPER TRAINING

CORRECT PROCEDURES BECOME A HABIT

SUSTAIN

MANAGERS COMMITTED

TO 5-S

5 Sasdfsdfssdfsdfdsfsdfsdfsfdsdfsdf

PARTICIPATION FROM ALL

EMPLOYEES

19

• Summary

– Cleaning serves many functions, including exposing abnormal and pre-failure conditions and building pride in the workplace

– Unless changes in work activities are standardized, things will go back to the way they were before improvement

– The Five Keys should be implemented on an ongoing basis, and should involve everyone

– Location Maps facilitate implementation

Keys 3, 4, 5: Shine, Standardize, Sustain

Reduces search time Eliminates defects Improves product quality Improves cost effectiveness Improves communication Eliminates work frustrations and delays Increases workplace safety Increases job satisfaction among workers

Benefits of Visual Factory System

. . .And, In Conclusion• Workplace Organization and Standardization begins with Project Identification and includes five keys:• Sort, Stabilize, Shine, Standardize and Sustain

• Red Tagging is a tool for Sorting

• Location Maps & Indicators are used in Stabilizing

Who Gets Most Benefited by 5S?

My Society

MyCompany

MyHouse

5S

Employees should adhere

Obedience

Discipline

Full – hearted approach towards given goal

5S

SESSION 125S – SUMMARY

DURATION : 30 MINUTES

1-11-2

1-31-4

2-12-2

2-32-4

‚R-‚P3-2

3-3

3-4

4-14-2

4-3

4-4

5-15-2

5-35-4

2-2

1S-SEIRI 2S-SEITON

3S-SEISO4S-SEIKETSU

5S-SHITSHUKE

RULE

A place for Everything,Everything in it’s place

Cleaning is Inspection

Standardization

Self-DisciplineSorting Out

5S Photo Display ( Fixed Point Photo )

Before After

Our Factory Environment…(Generally)

After Sorting...

1S

After Systematic Arrangement..

2S

After Cleaning...

3S

After Standardising...

4S

Building the Discipline…

5S

In a village there lived an saint old man who was kind hearted,

illiterate and a very good foreteller. Whatever he used to

foretell was final and everyone in the village used to go to him

even for little problems. They treated him next to god.

Morale

In the same village there lived an educated man. He was

quite egoistic and never liked the faith people had in that

saint. One day, he planned to make the saint feel ashamed.

As usual, All village people assembled for Saint’s Speech in

the morning. Educated man also joined the crowd. Suddenly,

He said, ”Saint!! In my hand, a small Dove is there. Can u tell

me the fate of this bird? If this bird is going to be dead or shall

remain alive!! Educated man thought if saint tells that the bird

shall remain alive, I’ll kill the bird and if he tells that the bird is

going to be dead, I shall release the bird..

What would have Saint replied..??

The bird live or die is in your hands

Like same story

Our Company 5S Implementation is in our hands only!!!!