house keeping & 5 s
TRANSCRIPT
HOUSE KEEPINGA base for any improvement
Even before you plan the direction you need to Even before you plan the direction you need to take, you must remove any obstacles to get a take, you must remove any obstacles to get a clear view of the current situation.clear view of the current situation.
House Keeping enhances the results of other House Keeping enhances the results of other activities and simplifies every day operations.activities and simplifies every day operations.
House Keeping must become a habit. It must be House Keeping must become a habit. It must be continuous, or at least continual activity.continuous, or at least continual activity.
WHAT IS HOUSE KEEPING Systematic approach to better workplace.Systematic approach to better workplace.
Involves arrangement, cleanliness, discipline and Involves arrangement, cleanliness, discipline and
maintenance of standards.maintenance of standards.
Assigns a place for every thing and ensures Assigns a place for every thing and ensures
everything in its place.everything in its place.
Is everybody’s responsibility.Is everybody’s responsibility.
Is the starting point of any improvement activity.Is the starting point of any improvement activity.
Means easy retrieval of information.Means easy retrieval of information.
WHY HOUSE KEEPING
LESS EQUIPMENT DOWN TIME.LESS EQUIPMENT DOWN TIME.
MORE USABLE SPACE.MORE USABLE SPACE.
PASSAGE WAYS ARE NEAT AND CLEAN.PASSAGE WAYS ARE NEAT AND CLEAN.
ABNORMALITIES NOTICED AT A GLANCE.ABNORMALITIES NOTICED AT A GLANCE.
ELIMINATES ACCIDENTS.ELIMINATES ACCIDENTS.
PRODUCTIVITY IMPROVEMENT.PRODUCTIVITY IMPROVEMENT.
WHY HOUSE KEEPING
EMPLOYEES FEEL GOOD IF THE WORK PLACE IS EMPLOYEES FEEL GOOD IF THE WORK PLACE IS
CLEAN.CLEAN.
SEARCHING IS AVOIDED.SEARCHING IS AVOIDED.
TIME WASTED IN HANDLING REDUCED.TIME WASTED IN HANDLING REDUCED.
NO UNNECESSARY SUPPLIES.NO UNNECESSARY SUPPLIES.
LESS REJECTION/REWORK.LESS REJECTION/REWORK.
BETTER PREVENTIVE MAINTENANCE.BETTER PREVENTIVE MAINTENANCE.
SIMPLE BUT IMPORTANT CONCEPT
A NEAT AND CLEAN FACTORY HAS HIGHER PRODUCTIVITY.
A NEAT AND CLEAN FACTORY PRODUCES FEWER DEFECTS.
A NEAT AND CLEAN FACTORY MEETS DEADLINES BETTER.
A NEAT AND CLEAN FACTORY IS A MUCH SAFER PLACE TO WORK.
THE FUNDAMENTAL TRUTH IF WE CANNOT KEEP OUR IF WE CANNOT KEEP OUR
WORKPLACESWORKPLACES CLEANCLEAN ORDERLYORDERLY ACCIDENT FREEACCIDENT FREE
NOBODY WILL BELIEVE WE NOBODY WILL BELIEVE WE CAN PRODUCE QUALITY CAN PRODUCE QUALITY GOODS OR ATLEAST SERIOUS GOODS OR ATLEAST SERIOUS ABOUT PRODUCING QUALITY.ABOUT PRODUCING QUALITY.
THE CONCEPT OF "5S" SEIRISEIRI SORTOUT (ORGANIZATION) SORTOUT (ORGANIZATION) SEITONSEITON SET IN ORDER (ORDERLINESS) SET IN ORDER (ORDERLINESS) SEISOSEISO SPICK & SPAN (CLEANLINESS) SPICK & SPAN (CLEANLINESS) SEIKETSUSEIKETSU STANDARDIZE (CLEAN UP) STANDARDIZE (CLEAN UP) SHITSUKESHITSUKE SUSTAIN SUSTAIN (DISCIPLINE) (DISCIPLINE)
THE FIRST PILLAR : SORT Sort Means That You Sort Means That You RemoveRemove
All Items From the All Items From the WorkplaceWorkplace That Are That Are Not Needed Not Needed for for CurrentCurrent Production Production OperationOperation..
SEIRI - SEGREGATION
THIS STEP DISTINGUISHES NECESSARY AND THIS STEP DISTINGUISHES NECESSARY AND
UNNECESSARY ITEMS AND ELIMINATES UNNECESSARY ITEMS AND ELIMINATES
UNNECESSARY ITEMS.UNNECESSARY ITEMS.
SORT THROUGH AND THEN SORT OUTSORT THROUGH AND THEN SORT OUT
SORT THROUGH WHAT YOU HAVE. IDENTIFY SORT THROUGH WHAT YOU HAVE. IDENTIFY
WHAT YOU NEED AND DISCARD WHAT IS WHAT YOU NEED AND DISCARD WHAT IS
UNNECESSARYUNNECESSARY
INDICATOR OF SUCCESS.INDICATOR OF SUCCESS.
AREA OR PERCENTAGE SPACE SAVED.AREA OR PERCENTAGE SPACE SAVED.
1. 1. CLASSIFICATION : SORT OUT.CLASSIFICATION : SORT OUT.
2. ELIMINATION : REMOVE UNNECESSARY 2. ELIMINATION : REMOVE UNNECESSARY ITEMS. ITEMS.
3. STORAGE : FREQUENT USE/ RARE USE.3. STORAGE : FREQUENT USE/ RARE USE.
CLOSE/ DISTANT LOCATION.CLOSE/ DISTANT LOCATION.
IDENTIFICATION OF ITEMS & IDENTIFICATION OF ITEMS & LOCATIONS. LOCATIONS.
4. FIX & SHARE RESPONSIBILITIES.4. FIX & SHARE RESPONSIBILITIES.
5. USE RED TAG SYSTEM.5. USE RED TAG SYSTEM.
6. MONITOR PROGRESS.6. MONITOR PROGRESS.
WHY SORT IS IMPORTANT??
A WORK ENVIRONMENT IN WHICHA WORK ENVIRONMENT IN WHICH TIMETIME MONEYMONEY SPACE SPACE ENERGY &ENERGY & EFFECTIVE RESOURCES MANAGMENTEFFECTIVE RESOURCES MANAGMENT
PROBLEMS IN PROBLEMS IN WORK FLOW WORK FLOW ARE REDUCED, ARE REDUCED,
CCOMMUNICATIONOMMUNICATION IS IMPROVED, PRODUCT IS IMPROVED, PRODUCT
QUALITYQUALITY IS INCREASED & IS INCREASED & PRODUCTIVITYPRODUCTIVITY IS IS
ENHANCED.ENHANCED.
MUDA ELIMINATION
WWASTEASTE
EELIMINATIONLIMINATION
LLEADS TOEADS TO
CCOSTOST
OOPTIMIZATION &PTIMIZATION &
MMANAGEMENTANAGEMENT
EEXCELLENCEXCELLENCE
THE WASTES IN THE SHOP FLOOR
INVENTORYINVENTORY
RELATED COSTSRELATED COSTS
TRANSPORTATIONTRANSPORTATION
QUANTITY HARDER TO SORTOUTQUANTITY HARDER TO SORTOUT
DESIGN OBSOLESCENCEDESIGN OBSOLESCENCE
QUALITY DEFECTS FROM WIPQUALITY DEFECTS FROM WIP
MACHINE BREAKDOWNSMACHINE BREAKDOWNS
SEIRI
FACTORY OFFICE HOUSE
SCRAPPED MACHINES/EQUIPMENTS
USED/BROKEN PENS BROKEN TOYS
REJECTED MATERIALS USELESS PAPERS/FILES OLD CLOTHES
EXPIRED GOODS OLD DIARIES BROKEN SUITCASE
SCRAPPED/BORKENTOOLS, PALLETS, BINS,TROLLEYS, ETC
BROKEN FURNITURE OLD SHOES
EXCESS PARTS OLD NOTICES/ LEAFLETS OLD LETTERS/MAGAZINES
UNUSED UTENSILS
SEIRIFREQUENCY ACTION
NOT USED FOR AYEAR OR MORE
CONSULT & DECIDEDISPOSAL. SEND TO SOMEOTHERPLACE/SELL/SCRAP
USED ONLY ONCEIN LAST 6-12MONTHS
STORE AT A DISTANCE / INRECORDS ROOM
USED ONLY ONCEIN LAST 2-6 MONTHS
STORE AT A CENTRALPLACE IN THE WORK AREA
USED MORE THANONCE A MONTH
STORE NEAR WORKPLACE
USED WEEKLY /DAILY / HOURLY
STORE NEAR WORKPLACE
THE SECOND PILLAR : SET IN ORDER
Set in Order Can Be Set in Order Can Be Defined As Defined As ArrangingArranging Needed Needed Items So That Items So That They Are They Are Easy to Use Easy to Use and and LabellingLabelling Them Them So That They Are So That They Are Easy to Find Easy to Find and Put and Put away.away.
SEITON --ARRANGEMENT
THIS STEP ENABLES DETERMINATION OF THE THIS STEP ENABLES DETERMINATION OF THE
TYPE OF STORAGE SYSTEM AND LAYOUT THAT TYPE OF STORAGE SYSTEM AND LAYOUT THAT
WILL GUARANTEE THAT REQUIRED AMOUNTS WILL GUARANTEE THAT REQUIRED AMOUNTS
OF NECESSARY ITEMS WILL BE EASILY OF NECESSARY ITEMS WILL BE EASILY
ACCESSIBLE.ACCESSIBLE.
SET THINGS IN ORDER BY CREATING PLACE SET THINGS IN ORDER BY CREATING PLACE
FOR EVERYTHING .FOR EVERYTHING .
PUT EVERYTHING IN IT’S PLACEPUT EVERYTHING IN IT’S PLACE . .
SEITON --ARRANGEMENT
KEEPING ACCESSIBILITY AS EASY AS KEEPING ACCESSIBILITY AS EASY AS
POSSIBLE .POSSIBLE .
USE THE PRINCIPLE OF WIDE RANGE USE THE PRINCIPLE OF WIDE RANGE
AND SHALLOW DEPTH FOR STORAGE.AND SHALLOW DEPTH FOR STORAGE.
TIME SAVED IN SEARCHING.TIME SAVED IN SEARCHING.
TIME SAVED IN HANDLING MATERIAL.TIME SAVED IN HANDLING MATERIAL.
PROBLEMS AVOIDED BY IMPLEMENTING SET IN ORDER
WASTE OF WASTE OF MOTIONMOTION SEARCHINGSEARCHING HUMAN ENERGYHUMAN ENERGY EXCESS INVENTORYEXCESS INVENTORY DEFECTIVE PRODUCTSDEFECTIVE PRODUCTS UNSAFE CONDITIONSUNSAFE CONDITIONS
HOW TO IMPLEMENT SET IN ORDER
DECIDING APPROPRIATE LOCATIONSDECIDING APPROPRIATE LOCATIONS LOCATE ITEMS IN THE WORKPLACE ACCORDING LOCATE ITEMS IN THE WORKPLACE ACCORDING
TO THEIR TO THEIR FREQUENCYFREQUENCY OF USE OF USE
PLACE FREQUENTLY USED ITEMS PLACE FREQUENTLY USED ITEMS NEARNEAR THE THE
WORKPLACEWORKPLACE
STORE INFREQUENTLY USED ITEMS STORE INFREQUENTLY USED ITEMS AWAYAWAY FROM FROM
THE PLACE OF USE.THE PLACE OF USE.
A A LET GOLET GO ARRANGEMENT FOR TOOLS SO THAT ARRANGEMENT FOR TOOLS SO THAT
THEY GO BACK TO ORIGINAL PLACE OF STORAGETHEY GO BACK TO ORIGINAL PLACE OF STORAGE
HOW TO PROMOTE GOOD ORDER
Seldom used, enclose in a separate designated Seldom used, enclose in a separate designated
place.place.
THINGS NOT NEEDED:THINGS NOT NEEDED:
No potential use, immediate disposal after careful No potential use, immediate disposal after careful
analysis.analysis.
Potentially useful, move to a separate Potentially useful, move to a separate
designated place.designated place.
Require special arrangement disposal. Require special arrangement disposal.
THE THIRD PILLAR : SHINE Shine Means Sweeping Shine Means Sweeping
Floors, Whipping off Floors, Whipping off Machinery, and Machinery, and Generally Making Sure Generally Making Sure That Everything in the That Everything in the Factory Stays Clean.Factory Stays Clean.
SEISO - CLEANING
This step eliminates Dirt, Dust and other foreign This step eliminates Dirt, Dust and other foreign
matter to make the workplace clean.matter to make the workplace clean.
Clean Equipment,Furniture,Notice Boards Clean Equipment,Furniture,Notice Boards
Records Etc.Records Etc.
Keep the workplace Spotless.Keep the workplace Spotless.
Sweeping,wiping,polishing,painting Etc.Sweeping,wiping,polishing,painting Etc.
THE FOURTH PILLAR :STANDARDIZE
Standardize Is The Standardize Is The Result That Exists Result That Exists When the First Three When the First Three Pillars - Sort, Set in Pillars - Sort, Set in Order and Shine Are Order and Shine Are Properly Maintained.Properly Maintained.
STANDARDIZATION
Set in Order
Machinery
WhereThingsAre Kept
OPERATION
Critical Processes
Communication
Inventory
STANDARDIZATIONSTANDARDIZATION
PROVIDE OBJECTIVES AND INDICATE TRAINING GOALS.
PROVIDE A BASIS FOR TRAINING
CREATE BASIS FOR AUDIT AND DIAGNOSIS.
PROVIDE A MEANS FOR PREVENTING RECURRENCE OF ERRORS AND MINIMIZING VARIABILITY.
SEIKETSU - STANDARDISATION
TO ESTABLISH STANDARDS TO TO ESTABLISH STANDARDS TO MAINTAIN THE IMPROVEMENTSMAINTAIN THE IMPROVEMENTS
CREATING RULES FOR CHECKING & CREATING RULES FOR CHECKING & COUNTERMEASURES.COUNTERMEASURES.
VISUAL CONTROLS FOR STANDARDS VISUAL CONTROLS FOR STANDARDS AND TO REVEAL ABNORMALITIESAND TO REVEAL ABNORMALITIES
TO PREPARE CHECKLISTS AND TO PREPARE CHECKLISTS AND ADHERE TO AVOID MISTAKESADHERE TO AVOID MISTAKES
HOW TO IMPLEMENT STANDARDIZE
VISUAL 5SVISUAL 5S ANYONE SHOULDANYONE SHOULD
DISTINGUISH NORMAL & DISTINGUISH NORMAL &
ABNORMAL CONDITIONS.ABNORMAL CONDITIONS.
AT A GLANCEAT A GLANCE
FIVE MINUTE 5SFIVE MINUTE 5S
HOW TO IMPLEMENT STANDARDIZATION
AUDIT THE SHOP FLOORAUDIT THE SHOP FLOOR
5S PROJECTS5S PROJECTS
REVIEWREVIEW
THE FIFTH PILLAR : SUSTAIN
Sustain means Sustain means making a habit of making a habit of properly maintaining properly maintaining correct procedures.correct procedures.
SHITSUKE - DISCIPLINE
THIS STEP IS TO ENSURE THAT EVERYONE THIS STEP IS TO ENSURE THAT EVERYONE
STICKS TO THE RULES SCRUPULOUSLY AND STICKS TO THE RULES SCRUPULOUSLY AND
MAKES IT A HABITMAKES IT A HABIT
CREATE GENERAL AWARENESS ABOUT 4S.CREATE GENERAL AWARENESS ABOUT 4S.
TRAINING TO EVERYONE.TRAINING TO EVERYONE.
DEVELOP NORMS AND MONITOR SUCCESS.DEVELOP NORMS AND MONITOR SUCCESS.
SHITSUKE - DISCIPLINE
High employee Morale.High employee Morale.
Involvement of People in the Movement.Involvement of People in the Movement.
SEIKETSU - TRAINING & DISCIPLINE
EVERY ONE IS STICKING TO THE EVERY ONE IS STICKING TO THE RULES AND STANDARDSRULES AND STANDARDS
PRACTISE BY EVERY ONE - MAKES PRACTISE BY EVERY ONE - MAKES PERFECTPERFECT
GOOD TRAINING FOR BASIC, GOOD TRAINING FOR BASIC, HABITUAL MOVEMENTS & ACTIVITIESHABITUAL MOVEMENTS & ACTIVITIES
5S IMPLEMENTATION
CONTINUING TO LEARN MORE ABOUT THE 5SCONTINUING TO LEARN MORE ABOUT THE 5S
HELPING TO EDUCATE YOUR CO-WORKERS HELPING TO EDUCATE YOUR CO-WORKERS
ABOUT 5SABOUT 5S
BEING ENTHUSIASTIC ABOUT 5S BEING ENTHUSIASTIC ABOUT 5S
IMPLEMENTATION.IMPLEMENTATION.
HELPING TO PROMOTE 5S IMPLEMENTATION HELPING TO PROMOTE 5S IMPLEMENTATION
EFFORTSEFFORTS..
5S TRAINING
1.1. THERE CAN BE NO TQM WITHOUT 5 S.THERE CAN BE NO TQM WITHOUT 5 S.
2. A DIRTY FACTORY OR OFFICE CANNOT 2. A DIRTY FACTORY OR OFFICE CANNOT
PRODUCE QUALITY PRODUCTS OR PRODUCE QUALITY PRODUCTS OR
SERVICE.SERVICE.
3. CLUTTER HIDES THE PROBLEM. A NEAT 3. CLUTTER HIDES THE PROBLEM. A NEAT
WORKPLACE PROMOTES EASY WORKPLACE PROMOTES EASY
DISCOVERY OF ABNORMALITIES. DISCOVERY OF ABNORMALITIES.
5S IS THE STARTING POINT FOR ALL 5S IS THE STARTING POINT FOR ALL
WORKPLACE IMPROVEMENTS, WORKPLACE IMPROVEMENTS,
PRODUCTIVITY, QUALITY, COST, PRODUCTIVITY, QUALITY, COST,
DELIVERY, SAFETY, SERVICE and DELIVERY, SAFETY, SERVICE and
MORALE.MORALE.