intimate fashion 5s
TRANSCRIPT
To Have the Right Things In the Right PlaceMaking the Workplace Bright and Productive
Intimate’s 5S Vision
From Basics to Benchmarks
Intimate’s 5S Journey
5S @ Intimate
Our 5S journey started during mid 2000 after seeing our Srilanka factory “BODYLINE Pvt. Ltd “
Training program was conducted for all employees about 5S
Posters were put up at all strategic locations in the factory about 5S
A contest was launched to all the employees for designing a suitable logo for the 5S movement at Intimate Fashions
Seiri day was celebrated to launch the first step of 5S on 10th October , 2000
SEITON @ Intimate
SEISO @ Intimate
SEIKETSU @ Intimate
SHITSUKE @ Intimate
SEIRI @ Intimate
5S is a simple but highly effective set of techniques
5S methodology was developed in Japan
5S is the foundation for any continuous improvement
5S removes waste from work environment through
better workplace organization, standardization, visual
communication and general cleanliness
5S factories are so well organized that abnormal situations
will be readily apparent
What is 5S ?
What are the 5Ss ?
5Ss5Ss Japanese English Meaning
1 S SEIRI SORT Remove unwanted items
2 S SEITON SYSTEMATIC
ARRANGEMENT
A place for everything and everything in its place
3 S SEISO SPIC&SPAN Cleaning with inspection
4 S SEIKETSU STANDARDISE Establish Standards for first 3Ss
5 S SHITSUKE SELF DISCIPLINE
Sustain & improve the first 4Ss
SEIRI- SORT
Remove waste, scrap, unused, sub-standard, excess items from
the workplace
Change the mental model of “Do not throw it away-it might
come in useful some day”
An effective visual method to identify & remove these
unwanted items is called Red Tagging
Seiri is eliminating unnecessary items from the workplace.
Space is freed for better utilization. Ensures Safety
Remove unwanted items
All unwanted items to be removed and placed in a
specially demarcated area called red tag area.
Unwanted items to be tagged with a red tag slip
Red tag slip will describe the item, quantity and date of
tagging
This process is for evaluation of the red tagged items
Occasionally used items are moved to a more organized storage
location outside of the work area from where unwanted items are
discarded
Guidelines to be framed for red tagging to prevent loss of
useful items
Red Tagging
SEITON-SYSTEMATIC ARRANGEMENT
Keep the right things in the right place and replace them in their respective place after usage
Use proper visual identification indicators Make sure storage is safe, to protect the item being
stored and also to prevent people from harming themselves when storing and retrieving
Do not store heavy items at the top making storage cupboards unstable
Seiton is keeping the needed items (those remaining after Sort) in the correct place to allow for easy and quick retrieval.
A place for everything and everything in its place
Better Inventory management.
Reduces Search time.Easy and Quick retrieval.
SEISO-SPIC&SPAN
Spend at least 5 Minutes daily for cleaning
Use appropriate tools for cleaning
While Cleaning also inspect for damage,defects and potential problems
Clean the Hidden areas also
Cleaning without care can cause more damage
Inculcate the mindset “It is My Duty to Clean My Place”
Seiso is Keeping the work place clean and also inspecting while cleaning
Cleaning with meaning
Equipment life is improved.Future problems are proactively identified and corrected
SEIKETSU- STANDARDISE
Establish uniform standards and procedures for labeling,
colour codes, indicators and safety norms
Display visual signage and control wherever possible
Establish proper Checklists, Responsibility Lists and
Schedules
Seiketsu is developing standards & responsibilities for the first 3Ss
Increases Quality & Productivity. Mistakes are eliminated
Establish Standards for first 3Ss
SHITSUKE-SELF-DISCIPLINE
Provide continuous guidance and training
Conduct regular 5S audits , display the result
Analyze audit findings & act
Create Interest & Involvement thro’ publicity & competitions
Ensure everyone is committed to “5S is my Responsibility”
SHITSUKE is perhaps the toughest of the 5S’s
Shitsuke is to implement mechanisms that are required to ensure the first 4Ss
5S becomes a Habit
Sustain & improve the first 4Ss
Seiri day was inaugurated by H.E. Mr. Tetsuya Unno the Vice Consul at the Consulate General of Japan for South India
The Chief guest unveiled the 5S logo
Prizes were distributed to the winners of the logo contest. (4 prizes out of 65 entries)
Red tag areas demarcated in every department
Red tags printed and issued to every department
Seiri was done throughout the factory on that day and all the red tagged items were moved to a common red tag area for the factory
SEIRI Day @ Intimate
SEIRI Day @ Intimate
Red Tag
SEIRI on Notice Board
Locker area
Main Entrance
Pathway to Reception
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Main Entrance
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Pathway to Reception
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Front Portico
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Entrance to Office
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Reception
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Office Corridor
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Way to Production Floor
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Sewing Floor
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Material Testing Lab
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Facility Block
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Facility Block
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Canteen Service Counter
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Landscaping
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Landscaping
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Toilet
Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202
Road to Loading Deck
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Stationery Template
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Visual Identification
Wrong placement
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Key Listing
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Staff Tracer Board
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Labels for Switch & Lights
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Medical Center
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Finished Goods Packing Area
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
WIP (1,50,000 components/line)
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
5S TEAM FORMATION
5S REVIEW BOARD
CEO & HOD’s
5S CHAMPION
STANDARDIZATION
TEAM
TRAINING
TEAM
AUDIT
TEAM
PUBLICITY
TEAM
Team Leader Team Leader Team Leader Team Leader
Members Members Members Members
Review once in 2 mths
New team every year
Chosen from volunteers
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
5S Team’s Responsibilities
• Standardization TeamStandardization Team
– To introduce standards for the first 3SsTo introduce standards for the first 3Ss
• Training TeamTraining Team
– To provide continuous education to all employees on 5STo provide continuous education to all employees on 5S
• Audit TeamAudit Team
– To schedule and conduct 5S auditsTo schedule and conduct 5S audits
• Publicity TeamPublicity Team
– To innovatively find ways of creating interest & To innovatively find ways of creating interest &
involvement on 5S with our employeesinvolvement on 5S with our employees
– To spread the awareness on 5S in our societyTo spread the awareness on 5S in our society
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Training for Bus,Van & Car Drivers
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
5S Audits in Floor
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Audit Results - Department
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
Audit Results - Intimate
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
5S Corner
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202
5S @ Home - Home Kit
Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202.
5S @ HOME – One of Our Employee’s Home
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
INTEROFFICE COMMUNICATION
PURCHASE DEPARTMENT
TO : DATE : FROM : REF NO : SUBJECT : Best regards,
Interoffice Memo – Approved Format
Other Documents standardized are • Business Correspondence Letter• Minutes of Meeting• Fax Communication
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Meeting Room – Status Indicator
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Tiger Lines
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Electrical Switch panel
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Air Conditioner Chiller Plant
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Less Frequent
File Colour Codification
Department colour
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Head Supervisor Production Mechanic
FINISHED GOODS Sewing Machine Operator
Colour Coding for Uniforms Pregnant
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
INTEROFFICE COMMUNICATION
PURCHASE DEPARTMENT
TO : DATE : FROM : REF NO : SUBJECT : Best regards,
Interoffice Memo – Approved Format
Other Documents standardized are • Business Correspondence Letter• Minutes of Meeting• Fax Communication
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Meeting Room – Status Indicator
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Tiger Lines
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Electrical Switch panel
Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202
Air Conditioner Chiller Plant