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5S Seiri Seiton Seiso Seiketsu Shitsuke
5S is a process set down by the Japanese to maintain house-keeping. This is the DNA for any developmental program. Without implementing 5S, one cannot progress in any developmental activity. 5S helps us to keep the environment clean, helps us to identify waste, excess, non-moving that are unhealthy to an organization. A kitchen in every household is the best example for 5S maintenance. One does not need to go for plant tours instead observe your kitchen. At the least, your spouse would be happy enough that you are paying attention to her. 5S is not one day activity or a flavor of the month. It is a continuous process and one should keep on doing it day-in and day-out. Seiketsu Shitsuke
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Quality Improvements JAPAN U.S.A INDIA 1980 1950 1960 1970
This graph indicates the quality improvements do increase dramatically if 5S is followed. Basically, Indians do possess the lacuna of untidyness and we live with it. If we start implementing 5S, it will not take years for us to catch the leaders. INDIA 1980 1950 1960 1970
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1. 5S Principles Every body is involved, Co-operative effort
Elimination of waste Every body is involved, Co-operative effort Attack root cause Human being is not infallible Our human body is the right example of processing the elimination of waste. Imagine a day without being making a visit to toilet. What will be our status? Similarly, any waste that is generated has to be purged or removed. This is not the duty of any single person but everyone. However, how long one has to keep on purging the waste. Of course one gets tired of this activity. If you do not want to get bored, then find out the root cause for the waste generation and then attack it. Infallible means “sure to succeed”. To Err is human, and to prevent him erring repeatedly, 5S is essential.
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2. Objectives Improve housekeeping
Make every individual responsible for housekeeping Beautify by simple means Productivity improvement by saving time, space etc. It is human nature for every human being to project himself presentable or beautiful. So, why not the place we work in? Don’t we keep our living rooms presentable? Then why cant we do the same to our workplace? In house, every family member does his part to keep it clean and here also we follow the same principle. We do not need an interior decorator to beautify the shop but simple things would do. Mind it “winners do not do different things but do things differently”. Obviously, by keeping our house clean, we get indirect benefits in terms of time saving etc.,
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3. 5S’s Seiri - Sorting Seiton - Systematic arrangement
Seiso Cleaning Inspection while cleaning Seiketsu - Standardization Shitsuke - Self Discipline What makes 5S? The 5 Japanese words starting with letter S and its equivalent English Words that relate to the 5S activities.
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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. One cannot read one’s mind but can make out an impression by seeing the appearance. Perception is more than reality. If we do not present ourselves well, we cannot sell ourselves. If we do not imbibe the discipline of cleanliness, even our spouses would leave us for good.
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COMMON MIND SETS… Its an additional burden. Too busy to do 5S activities. Why clean it? It will get dirty again We cannot change the existing setup. More work pressure – No time for these things One cannot read one’s mind but can make out an impression by seeing the appearance. Perception is more than reality. If we do not present ourselves well, we cannot sell ourselves. If we do not imbibe the discipline of cleanliness, even our spouses would leave us for good.
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SEIRI = Sorting – Just in Case to “Just-in-Time”
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
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SEIRI = Sorting – Fight with habits
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SEIRI = Sorting 3 Categories
√ - Item Required X – Item Not Required ? – Undecided Move to Red Tag Holding Area
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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. Item is needed but once in a blue-moon 4. Contingency Parts Critically decide the quantity of contingency parts to be retained and criteria for such parts
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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
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Identifying unnecessary
Seiri = Sorting Identifying unnecessary 1. Parts & Work in Process (WIP) Things fallen back behind the machine or rolled under it Broken / some 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..
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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..
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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, used tea-cups etc. 5. Passages and Corners WIP material waiting for decision or dispatch 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..
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Identifying unnecessary
Seiri = Sorting Identifying unnecessary 8.Floor, Pits, Partitions Defective parts Protection caps, shoe covers Packing material, stickers, barcodes, cut-leads Hardware items, small items, runners, plastic granules Even tools, tooling Items dropped on the floor are never picked 9.Computer Hard Disk Many unwanted, outdated, temporary files pile up Old dated mails still remaining in inbox and sent items Deleted mails not being purged when closed Recycle bin not emptied
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Seiri = Sorting TAGGING
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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.
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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
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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
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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 (30 sec to locate an item) Indicator - Time saved in material handling
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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
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Seiton = Systematic Arrangement
How to achieve Systematic Arrangement ? Decide where things belong Decide how things should be put away Obey the Put away rules
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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 & color contd..
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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, color code them. Obey the rules - Put the things back to their location after their use
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Seiton = Systematic Arrangement
USE : 1 ) Signboards 2) Color codes 3) Outline markings 4) Labels
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Seiton = Systematic Arrangement
Functional Storage
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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
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Seiton = Systematic Arrangement
Same category of material may be stored in one location. Eg. Fasteners, Seals , resistors 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
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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
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Seiton = Systematic Arrangement
Wires and Ducts - Color 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
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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
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Seiton = Systematic Arrangement
Oils & Lubricants - Reduce number of oils used (Standardize) - Color code for oil - Safety aspects - fire prevention, pollution, leak, spillage Instrumentation & Measuring Devices - Label them, show direction of flow
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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
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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
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= 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 color =Hisses - Cracks
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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
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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
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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
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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
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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
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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.
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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.
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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 - Color coding - Early detection of problem and early action Success Increase in 5S indicator Indicator
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SEIKETSU = Standardization
Tools used for analysis : MTTR MTBF OEE
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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
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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
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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
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Seiketsu = Standardization
Some methods for visual communication Color coding Use of Labels Danger alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators
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Seiketsu = Standardization
Some methods for visual communication Labels Precision management labels Inspection labels Temperature labels Responsibility photos
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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
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Seiketsu = Standardization
Some everyday visual management examples Traffic signal Zebra crossing In car - Petrol indicator - Speed indicator Direction arrows Electric danger sign Toilet
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Seiketsu = Standardization
Some visual communication signs
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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
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SHITSUKE = Self Discipline
Activities : 5S Committee 5S Training 5S Competition / evaluation 5S Month Posters , Literature etc.
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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
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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.
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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
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Machine building Bay
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Heat Treatment Area
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Heat Treatment Area
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Machine Shop
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End of the presentation & Beginning of 5S activities….
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