5s Training Slides 138
5s Training Slides 138
5s Training Slides 138
INDIA
1950 1960 1970 1980
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1. 5S Principles
Elimination of waste Every body is involved, Cooperative effort Attack root cause Human being is not infalliable
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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.
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3. 5Ss
Seiri Seiton Seiso
- Sorting
- Systematic arrangement
5S
If we do not do 5S, we cant 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.
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SEIRI = Sorting
Meaning
Distinguish between necessary and unnecessary items and eliminate the unnecessary items Establish a criteria for eliminating unwanted items Eliminate unwanted items either by disposing them or by relocating them. Area saved or percentage of space available
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
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Seiri = Sorting
What is unnecessary
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
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Organization
Frequency of use Storage Method
LOW
*Things you have not used Throw them out in the past one year *Things you have used once Store at distance OR in the last 6-12 months Keep in store
*Things you have used only Store it in central place once in the last 2-6 months in your zone
*Things used more than once Store it in central place a month in your zone
HIGH
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..
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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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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..
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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
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Seiri = Sorting
Improvement methods
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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Seiri = Sorting
Seiri = Sorting
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How to achieve Systematic Arrangement ? Decide where things belong - Standardize Nomenclature
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.
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4) Labels
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Functional
Storage
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Usage Store frequently used material Frequency 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
Functional Storage
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Category
Operation Wise
Functional Storage
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- Follow straight line, right angle rule - Nothing shall be kept outside the boundaries
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Blades, Dies, Other important consumables - Store them in the protected place
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SEISO = Cleaning
Meaning
Cleaning trash, filth, dust and other foreign
matter. Cleaning as a form of Inspection
- Keep workplace spotlessly clean - Inspection while cleaning - Finding minor problems with cleaning inspection - Reduction in machine down time
- Reduction in no. of accidents
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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
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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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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
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Seiso = Cleaning
Seiso = Cleaning
Oils
No oil, Low oil, leakage, filter clogging, dirty oil, dirty or bent oil lines, clogged drainage, oil spillage, worn& torn ports etc.
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Seiso = Cleaning
Oil tanks, motors, heater, axles, control panels, washing/ cleaning water, bearing, wiring etc.
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Seiso = Cleaning
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Seiso = Cleaning
Hydraulics
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Seiso = Cleaning
bearings etc.
Electrical
Control panel, lamps, light, switch, sensors, wiring, ducts, fuses etc.
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Seiso = Cleaning
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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) - Innovative visual management - Colour coding - Early detection of problem and early action Increase in 5S indicator
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SEIKETSU = Standardization
Japanese Meaning : Dictionary meaning unsoiled things, purity and cleanliness Clean manners , Clean cloths, clean politician It is the proof that 3 Ss are being faithfully carried out.
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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 Colour 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 labels
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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 etc.
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- Participation of everyone in developing good habits - Regular audits and aiming for higher level High employee morale
Involvement of all people
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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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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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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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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
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Implementation Target
TOTAL FACTORY 400 people/month to be trained Every 3 month 25% area will be covered
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