5S - BASIC TRAINING What is 5S and why do we want to do it? ALOK SHARMA 22\06\2010

What is 5S ? Seiri – Sort (housekeeping) Seiton – Systematic Arrangement (workplace organization) Seiso – Shine (Cleanup) Seiketsu – Standardize Shitsuke – Sustain (Self Discipline)

What is 5S ? 5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems). These are foundational to Kaizen (continuous improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts. 5S is one of the activities that will help ensure any company’s survival.

5S 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

Some New Words Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes Some Japanese words one need to know: Kaizen-(pronounced “kai zen”) – Continual improvement Muda-(pronounced “moo da”) - waste Gemba-(pronounced “gim ba”) – workplace Kanban-(pronounced “kon bon”) - Pull type inventory control system. Items are only produced to meet customer needs. The request to produce more is signaled from an upstream operation and/or customer orders.

KAIZEN: What it is? Process Improvement Observation Use of New Paradigms Short Time Zero Investment Human Development & Empowerment Profits & Savings - Plenty

KAIZEN KAI ZEN ALWAYS GOOD CONTINUAL IMPROVEMENT CHANGE FOR THE BETTER

KAIZEN IS A JOURNEY FROM: EVENT RESULT GROSS ENFORMENT OF CHANGE TO CAUSE TO PROCESS TO MICRO TO INDUCEMENT OF CHANGE

CONTINUOUS CONTINUAL KAIZEN IS CONTINUAL IMPROVEMENT TIME TIME

KAIZEN: KNOW THE REALITY THROUGH YOUR SENSE OBSERVATION INTELLIGENCE PHYSICAL EFFORT PARADIGM OF HIGH PRODUCTIVITY & QUALITY

KAIZEN AT GEMBA GEMBA: PLACE OF WORK GEMBA is where . . . Value is added Actual work is done to meet customer requirement Problems are solved Staff is responsible for providing support, not for giving instruction

1. 5S Principles Elimination of waste Every body is involved, Co-operative effort Attack root cause Human being is not infallible

2. Objectives Improve housekeeping Make every individual responsible for housekeeping Beautify by simple means Productivity improvement by saving time, space etc.

(Systematic Arrangement) The ‘S’ Japanese Word What is involved Objective 1S SEIRI (Sorting Out) Segregate necessary from unnecessary Remove what is not required Decide on frequency of sorting Saving and recovering Space 2S SEITON (Systematic Arrangement) Arranging in order Place for everything, Everything in its place Minimizing search time 3S SEISO (spic and Span) Cleaning the work place/ equipment Attaining the warning bell Inspecting for problems Taking corrective actions faster 4S SEIKETSU (Standardization) Working Methodology (Procedures & WI) Achieving higher productivity and better quality 5S SHITSUKE (Self Discipline) Forming the habit in form of Training and Discipline Doing it right at First Time

SEIRI = Sorting Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items Activity Establish a criteria for eliminating unwanted items Eliminate unwanted items either by disposing them or by relocating them. Success Area saved or percentage of space available Indicator

SEIRI = Sorting Japanese Meaning : The Japanese meaning of “Seiri” is to straighten and contain. - Get rid of waste and put it in order according to rules

Respiratory System 1 ‘S’ - SEIRI 1 ‘S’ – Our respiratory system sorts oxygen and other gases. And exhales other gases which are unwanted for our body

1S – SEIRI : SORTING 1 ‘ S’ Sort for . . . Not Needed at All Needed but not Now Needed but not here Needed but not so much Quantity 1 ‘ S’ WANTED UNWANTED

What is unnecessary Seiri = Sorting 1. Item is not needed 2. Item is needed however quantity in stock is more than what is needed for consumption in near future 3. Contingency Parts Critically decide the quantity of contingency parts to be retained and criteria for such parts

Organization LOW AVERAGE HIGH Frequency of use Storage Method Throw them out *Things you have not used in the past one year LOW *Things you have used once in the last 6-12 months Store at distance OR Keep in store *Things you have used only once in the last 2-6 months Store it in central place in your zone AVERAGE *Things used more than once a month Store it in central place in your zone HIGH *Things used once a week Store near the workplace *Things used daily or hourly Store near the workplace

Identifying unnecessary Seiri = Sorting Identifying unnecessary 1. Parts & Work in Process (WIP) Things fallen back behind the machine or rolled under it Broken items inside the machine Things under the racks/ platform Extra WIP Stock of rejected items Items accumulated over period for rework Material awaiting disposal decision Material brought for some trial, still lying even after trial Small qty of material no longer in use Contd..

Identifying unnecessary Seiri = Sorting Identifying unnecessary 2. Tools, Tooling, Measuring devices Old jigs, tools not in use are lying Modified tools, tooling for trial, are lying after trial Worn out items like bushes, liners, toggles etc. lying Broken tools, bits, etc. may be lying Measuring equipment not required for the operation being performed , is lying 3. Contingency Parts Many times storage place for contingency parts become a last refuge for broken parts, surplus items and things nobody is likely to use Contd..

Identifying unnecessary Seiri = Sorting Identifying unnecessary 4. Shelves and Lockers Shelves and lockers tends to collect things that nobody ever uses , like surplus, broken items etc. 5. Passages and Corners Dust, material not required seem to gather in corner 6. Besides Pillars and under the stairs These places tends to collect junk, spittoon etc. 7. Walls and Bulletin Boards Old out dated notices which have lost their relevance Posters or bulletins on wall Dust, remains of torn notices, cell tape pieces Contd..

Identifying unnecessary Seiri = Sorting Identifying unnecessary 8.Floor, Pits, Partitions Defective parts Protection caps, covers Packing material Hardware items , small items Even tools, tooling Items dropped on the floor are never picked 9.Computer Hard Disk Many unwanted, outdated, temporary files pile up

Improvement methods Seiri = Sorting 1. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system e.g. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for system e.g. How to perform Seiri (sorting) 3. Check List A check sheet is used to decide what sort of main system and sub system are necessary.

Dealing with papers How to Reduce Papers on Your Table ? Seiri = Sorting Dealing with papers How to Reduce Papers on Your Table ? 1. Make a single pile of papers 2. Go through them and sort in following categories a) Immediate action b) Low priority c) Pending d) Reading material e) For information

Dealing with papers How to Reduce Papers on Your Table ? 4 D Principle Seiri = Sorting Dealing with papers How to Reduce Papers on Your Table ? 4 D Principle DO DELEGATE DELAY DUMP

Arranging things in systematic way Seiton : Systematic Arrangement PLACE FOR EVERYTHING, EVERYTHING IN ITS PLACE Arranging things in systematic way

2 ‘S’ – In our body there is a fixed place for every organ. 2 ‘ S’ - SEITON 2 ‘S’ – In our body there is a fixed place for every organ.

SEITION = Systematic Arrangement Meaning To determine type of storage and layout that will ensure easy accessibility for everyone . Activity - Functional storage - Creating place for everything and putting everything in its place Success - Time saved in searching Indicator - Time saved in material handling

SEITION = Systematic Arrangement Japanese Meaning: Dictionary meaning of Seiton is “to be correctly prepared” and “to prepare correctly”. In short these means : (a) arrange correctly in accordance with the correct method of doing activities and (b) make thorough preparations so that activities can be done even if they occur abruptly

Seiton = Systematic Arrangement How to achieve Systematic Arrangement ? Decide where things belong Decide how things should be put away Obey the Put away rules

Seiton = Systematic Arrangement How to achieve Systematic Arrangement ? Decide where things belong - Standardize Nomenclature - Determine an analytical method of storage Decide how things should be put away - Name & locations to everything. - Label both item and location - Store material functionally - Prevent mistakes with coding by shapes & colour contd..

Seiton = Systematic Arrangement How to achieve Systematic Arrangement ? Decide how things should be put away - Follow (FIFO) first in first out rule - If two identical items are to be located, then store them separately, - colour code them. Obey the rules - Put the things back to their location after their use

Seiton = Systematic Arrangement USE : 1 ) Signboards 2) Colour codes 3) Outline markings 4) Labels

Seiton = Systematic Arrangement Usage Frequency Store frequently used material near the workplace and less frequently at some distance Heavy material should be stored at lower levels/layers Place directly on the material handling device for ease of handling Weight & Shape of the Material Functional Storage

Seiton = Systematic Arrangement Same category of material may be stored in one location. e.g, Allen Screws, Oil Seals Category All items required for an operation may be stored in one location. e.g, Allen key, spanner etc hand tools required for setting m/c Operation Wise Functional Storage

Seiton = Systematic Arrangement Outlining and Placement Marks - Mark boundaries of dept., aisles, Machines - Follow straight line, right angle rule - Nothing shall be kept outside the boundaries Stands and shelves - Keep only required number of stands and shelves - Standardize height, size - Provide casters where necessary so that it can be moved

Seiton = Systematic Arrangement Wires and Ducts - Colour code - When there are multiple connections – bundle the wires, label them and make sure that they are in straight line /right angle and firmly anchored. Machine-tools & Tools - Put the tools in the order you need them - Location of the tool should be such that it can be put away with one hand - Try to eliminate some hand tools by permanently attaching it to the bolt head

Seiton = Systematic Arrangement Blades, Dies, Other important consumables - Store them in the protected place - Maintain these things regularly by applying rust preventive, oiling etc. WIP- Work In Process - Designate a place for each component/part - Decide on how much quantity to be stored - Ensure that there is no damage to good part during transit, they do not get rusty and they are not mislabeled

Seiton = Systematic Arrangement Oils - Reduce number of oils used (Standardize) - Colour code for oil - Safety aspects - fire prevention, pollution, leak, spillage Instrumentation & Measuring Devices - Label them, show direction of flow

Before sort after sort

Before sort after sort

3 ‘S’ Seiso : Cleaning KIKEN KITSUI KITENOI (DANGER) (PROBLEM) (DIRT) Clean the surroundings !

3 ‘ S’ - SEISO 3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc

SEISO = Cleaning Meaning Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of Inspection Activity - Keep workplace spotlessly clean - Inspection while cleaning - Finding minor problems with cleaning inspection Success - Reduction in machine down time Indicator - Reduction in no. of accidents

SEISO = Cleaning Japanese Meaning : Dictionary meaning “to clean up” and “getting rid of dirt and unclean items” While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection

Here cleaning means more than just keeping Seiso = Cleaning Here cleaning means more than just keeping things clean. Cleaning should be viewed as a form of Visual Inspection Preventive measures should be taken to tackle problems of dust, grim, burrs, leakage etc. Root cause of the problem should be identified and it should be eliminated

Devote 5 minutes everyday for cleaning your work area Seiso = Cleaning 5 Minutes Every day for cleaning Devote 5 minutes everyday for cleaning your work area Participation of everyone is required Attack hard to clean places regularly

Seiso = Cleaning EXAMPLE : PREPARE CHECKLIST FOR CLEANING SL.No TICK 1 Check Floors are clean 2 Check Work areas are clean 3 Check walls are clean 4 Check Pillars and Ceiling are clean 5 Check Windows are clean 6 Check Rooms and Electrical lights are clean

Seiso = Cleaning Seiso Cycle BEFORE WORK, CLEAN AND INSPECT THE MACHINERY TOOLS, JIGS & FIXTURES. BEGINNING OF WORK - DO TRIALS AND START UP DURING OPERATION - CLEAN, INSPECT, DISCOVER AND DEAL WITH ABNORMALITIES AFTER COMPLETION OF WORK - DISPOSE OFF AND GET RID OF UN-NECESSARY THINGS SEISO IS A PART OF GOOD WORKMANSHIP SEISO IS AN IMPORTANT PRE-CURSOR WITH 5S

Cleaning Oils Seiso = Cleaning Cleaning-Inspection points for most equipment Grime, clogging, dust balls, rust, leakage etc. Cleaning No oil, Low oil, leakage, filter clogging, dirty oil, dirty or bent oil lines, clogged drainage, oil spillage, worn& torn ports etc. Oils

Tightening Heat Seiso = Cleaning Cleaning-Inspection points for most equipment Loose bolts, welding detachment, loose parts, vibration or bumping noise, friction Tightening Oil tanks, motors, heater, axles, control panels, washing/ cleaning water, bearing, wiring etc. Heat

Breakage, Cracks Seiso = Cleaning Cleaning-Inspection points for most equipment Breakage, cracks, dent on sliding parts, handle has come off, broken switches, wire joints come off, wires are broken or crack, crack dial of various pre. gauges, meters etc. Breakage, Cracks

Pneumatics Hydraulics Seiso = Cleaning Function wise Cleaning check list of equipment Compressed Air lines, air valves, connections, meters, filters, reservoirs etc. Pneumatics Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc. Hydraulics

Mach. & Power Train Electrical Seiso = Cleaning Function wise Cleaning check list of equipment Motor fan, fan belt, couplings, Joints, pulleys, chains, pump bearings etc. Mach. & Power Train Electrical Control panel, lamps, light, switch, sensors, wiring, ducts, fuses etc.

Tooling Equipment Specific Seiso = Cleaning Function wise Cleaning check list of equipment Tools, fixtures, gauges, dies, measuring instruments, etc. Tooling Equipment Specific Furnaces, rollers, chutes, CNC machines, etc.

Before shine after shine

Before shine after shine

4 ‘S’ Seiketsu STANDARISATION

4 ‘ S’ - SEIKETSU 4 ‘S’ – In every human being the structure of fingers are same I.e. Standardised. If it is not so, then we call it is abnormal.

SEIKETSU = Standardization Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure) Activity - Innovative visual management - Colour coding - Early detection of problem and early action Success Increase in 5S indicator Indicator

SEIKETSU = Standardization Japanese Meaning : Dictionary meaning “unsoiled things, purity and cleanliness” Clean manners , Clean cloths, clean politician It is the proof that 3 S’s are being faithfully carried out.

SEIKETSU = Standardization Tools used for analysis : MTTR : Mean Time To Repair \ Recover MTBF : Mean Time Between Failures OEE : Overall Equipment Efficiency

Seiketsu = Standardization Regularizing 5S activities so that abnormalities are revealed Make it easy for everyone to identify the state of normal or abnormal condition For maintaining previous 3S, deploy visual management

Seiketsu = Standardization It has been estimated by scientific study that 60% of all human activities starts with sight 5S is easy to do once. It is consistency that is difficult. That is why Visual Management is so important, so that everybody will know that there is some problem. Visual Management

Seiketsu = Standardization What visual control communicates ? It grabs one or more of our senses in order to Alert us to an abnormality Help us recover quickly Promote adherence and prevention Enable successful self management

Seiketsu = Standardization Some methods for visual communication Colour coding Use of Labels Danger alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators

Seiketsu = Standardization Some methods for visual communication Labels Precision management labels Inspection labels Temperature labels Responsibility labels

Seiketsu = Standardization Points to remember in making visual control tools 1. Make them easy to see from distance 2. Put the display on the things 3. Everyone can tell what is right and what is wrong 4. Anybody can follow them and make necessary corrections easily 5. Work place should look brighter & orderly

Seiketsu = Standardization Some everyday visual management examples Traffic signal Zebra crossing In car - Petrol indicator - Speed indicator Direction arrows Electric danger sign etc.

Seiketsu = Standardization Some visual communication signs

5 ‘S’ Shitsuke SELF DISCIPLINE

ENSURE . . . Procedure & Work Instruction are correct. Standard are expressed in specific. Visual Aids are used. Train at all levels. Work ethics for effective management. Transparent & Discipline work culture.

5 ‘S’ – Every human body has its standard process which they maintain. 5 ‘ S’ - SHITSUKE 5 ‘S’ – Every human body has its standard process which they maintain.

SHITSUKE = Self Discipline Meaning Every one sticks to the rule and makes it a habit Activity - Participation of everyone in developing good habits - Regular audits and aiming for higher level Success High employee morale Indicator Involvement of all people

SHITSUKE = Self Discipline Japanese Meaning : Dictionary meaning is “learning of the manners” “having manners, dressing neatly” OR “training children for good customs”

SHITSUKE = Self Discipline Activities : 5S Committee 5S Training 5S Competition / evaluation 5S Month Posters , Literature etc.

Shitsuke = Self Discipline We need everyone to maintain 5S guidelines. To maintain DISCIPLINE, we need to practice and repeat until it becomes a way of life. Discipline is the Core of 5S

Shitsuke = Self Discipline Discipline means making a steady habit of properly maintaining correct procedure. Time and effort involved in establishing proper arrangement and orderliness will be in vain if we do not have discipline to maintain it.

Shitsuke = Self Discipline Pledge It shall be my constant effort to maintain my workplace in good order by Assigning a place for everything & keeping everything in its place Sorting out unwanted material periodically & discarding them Keeping my work area neat & clean everyday

ORGANIZATION Organization Departments into areas Coordinators at department level Coordinator at each area level Training for all Audit each area and make action check list Implement actions Audit and evaluation on continuous basis Organization

Some 5S Examples After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting) Before 5S

5S Pictures Before After ERAANHA 2004-11-01 1/2882-FCS 101 78 Uen Rev D

5S Pictures Before: Repair After ERAANHA 2004-11-01 1/2882-FCS 101 78 Uen Rev D

5S Pictures Before After ERAANHA 2004-11-01 1/2882-FCS 101 78 Uen Rev D

The Good, Bad and the Ugly First the Bad and the Ugly - Life Without 5S

The Good

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