Safety, Health & Environment Overview of 5S WELCOME Prashant Rane Safety, Health & Environment 26 May 2010

5S Principles Elimination of all types of waste Every body is involved, Team work Attack root cause Continual improvement is possible Mind set change, culture building

What are 5S ? 5S are five Japanese words beginning with S Involvement programme Participation programme Culture building path System for continual improvement of mind set of employees

5S is foundation for visual factory

What are the 5 S´s ? SEIRI Sorting / Organise SEITON Neatness SEISO Cleaning SEIKETSU Standardisation SHITSUKE Self Discipline SEIRI SEITON SEISO SEIKETSU SHITSUKE Development Time

Objectives 1S: Release the space 2S: Minimize searching and access time 3S: Zero Leakage : Zero Spillage : Make easy to clean and inspect : Zero Accident : Zero Breakdown : Zero Abnormality.

Objectives continued.. 4S : Zero rework : Zero internal rejection : Zero external rejection : Zero customer complaints : Zero variance on all targets and commitments

Objectives continued.. 5S : Zero violations of rules procedures and policies : Zero reminders

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

1S : 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 released as a percentage of space Indicator available

2S : 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 and access Indicator - Time saved in material handling

SEITION = Systematic Arrangement Easy to identify Easy to Locate Easy to Pickup and access Easy to keep it back Easy to Inspect Easy to read Easy to instruct

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

3S: 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 spillage, leakages, down time Indicator - Reduction in no. of accidents

SEISO = Cleaning Organise major initial cleaning Identify the Leakages and put tags Identify the spots difficult to clean Implement Projects to make cleaning easy Team involvement in projects

SEISO = Cleaning Develop cleaning checklist Train for doing root cause analysis

Seiso = Cleaning and Inspection 5-10 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 and Inspection Create a checklist for initial cleaning Where ? How ? (Equipment, Material, ...) How often ? (daily, weekly, ...)

SEIKETSU = Standardization Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure and standards) Activity - Innovative visual management - Colour coding - Early detection of problem and early action Success Improvement in 1S, 2S and 3S level Indicator Zero Rejections, Variance on targets

SEIKETSU = Standardization Seiketsu is result of first 3S implementation Systematic training on problem solving is must to all team members

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 Growth of the organisation

SHITSUKE = Self Discipline Develop the rules, procedures, practices, standards Train all the employees to understand and use No follow up is required No. chasing is required No Reminding is required No violations of norms or discipline Employee is proud of his role and activity

SHITSUKE = Self Discipline Activities : 5S Training 5S Month, exhibitions Posters , Literature etc. Periodic audits of the level of the 5S Worst photo contest Presentations by each team

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.

THNAKS