Quality Improvements JAPAN U.S.A INDIA 1980 1950 1960 1970

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

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

3. 5S’s Seiri - Sorting Seiton - Systematic arrangement Seiso - Cleaning Inspection while cleaning Seiketsu - Standardization Shitsuke - Self Discipline

5S If we do not do 5S, we can’t do any other work efficiently. They are features which are common to all places and are the indicators of how well an organization is functioning.

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 OTHER JAPANESE MEANINGS - farmland cultivation, Make an orderly system and straighten

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, Toolings, 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 eg. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for system eg. 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

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

SEITION = Systematic Arrangement The main target areas for Seri-Seiton improvement are : Tool-setting and preparation operations, line balancing and process planning, parts supply to assembly line, peak time problems etc. Improvement Methods Kit Method / Assembly box method / Outside tool setting Cassettisation / Parallel operations / Changes in assignment method

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 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 Functional Storage

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

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

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

= Trash = Dirt =Knocking = Loose parts = Leaks =Scattering Seiso = Cleaning Various Minor Defects = Trash = Dirt =Knocking = Loose parts = Leaks =Scattering =Skips =Curvature =Abrasion =Rust =Scratches =Eccentricity =Lurching =Abnormal =Vibration Movements =Abnormal =Heat =Abnormal Sounds smells =Faded colour =Hisses

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

equipment 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

equipment 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

equipment 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

equipment 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

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

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

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 MTBF OEE

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 c 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

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 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

Implementation Target TOTAL FACTORY 400 people/month to be trained Every 3 month 25% area will be covered