5S

Basics + 1
Seiri Seiton Seiso Seiketsu

5S

Shitsuke
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1. 5S Principles
Elimination of waste Every body is involved, Cooperative 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. 5Ss
- Sorting - Systematic arrangement - Cleaning Inspection while cleaning Seiketsu - Standardization Shitsuke - Self Discipline

Seiri Seiton Seiso

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.

8 WASTES D efect / Correction O verproduction W aiting N ot utilizing employee talents T ransportation / material movement I nventory M otion E xcessive processing
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Visual Factory-Information Gathering/Organization PAB = Process Analysis Board

From Each Department

Information Center
(Plant-wide Reporting)
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There are basically three different types of workplaces...

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1S 2S 3S 4S 5S

Sort Straighten Shine Standardize Self Discipline

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1S Sort
Segregate What Is Needed, Needed Later, and Not Needed Discard What Is Not Needed Segregate Needed Items By Frequency of Use

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Where to Perform

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Item Name &/or Description: Department: Value per Item:

Classification:

5S --- RED TAG

Ent er # in box

1. 2. 3. 4.

Raw Material Work-in-Process Component Finished Product

5. 6. 7. 8.

Machine / Equipment Mold / Jig Tool / Fitting Other______________

Reason:
Ent er # in box

1. 2. 3.

Unnecessary Defective Leftover Material

4. 5.

Unknown Other______________

Action:
Ent er # in box

1. Eliminate 2. Return 3. Move to Red Tag Storage 4. Other_______________

Completed:

C E N GL EX X X (-)

Tag Attached:

Action Taken:

Year_____ Month_____ Day____

Year_____ Month_____ Day_____

File completed Tag at ____________

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Sort

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2S
Straighten

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Small Claw Hamme r

Large Claw Hamme r

Small Cresc ent Wren ch

Large Cresc ent Wren ch

Flat Tip Screw driver

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Stage 1

Stage 2

Stage 3

Stage 4

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Before

After

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Before

After

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After

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Before

After

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3S
Shine

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Why Shine?

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Shine Targets

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5S Assessment

Location Being Audited:

{Enter Location here}

5S

To-Do Items
Remove unneeded equipment, tools, furniture, etc. Provide information on department PPB Review excess inventory, supplies, parts, or materials Identify existence of safety hazards (water, oil, chemical, machines, extension cords, etc.)

Observed Condition

Improvement Action

Score Sheet

Remove unnecessary items. All items not required for performing operations are removed from the work area. Only tools and products are present at workstation

Sort

Correct location for items are identified Items are placed in their correct locations Aisle ways, workstations, equipment locations are indicated Items are put away immediately after use Inventory or WIP height and quantity limits are obvious

Floors, walls, stairs, and surfaces are free of dirt, oil and grease Equipment is kept clean and free of dirt, oil, and grease Cleaning materials are easily accessible Lines, labels, signs, etc. are clean and not damaged No other cleaning problems (of any kind) are present

Storage of cleaning equipment: All cleaning equipment stored in a neat manner; handy and readily available when needed Items on floor: Work-in-process, tools and any other material are not left to sit directly on the floor. Large items such as tote boxes are positioned on the floor in clearly marked area, identified by painted or taped lines. Storage and arrangement:: Boxes, containers, and materials are always stored neat and at correct work angles convenient to the operators where appropriate. When items are stacked evenly or in a manner that would not cause them to toppling over. Storage areas are provided for all necessary items at POUS (Point-Of-Use Storage). No items are placed on top of machines, cabinets, and equipment. Unidentified items can not lean against walls or columns. Operating equipment/machinery: Each piece of equipment/machinery has guards and deflectors that prevent debris from falling uncontained to the floor. Document storage: Only documents necessary to the operation are stored at the workstations and are stored in a neat and orderly manner. Tool and gauges arrangement: Tools, gages and fixtures are arranged neatly and stored, kept clean and free of any risk of damage. Aisle ways maintenance: Aisles are always free of materials and obstructions; nothing is placed on the lines and objects are always placed at right angles to the aisles where appropriate. Equipment painting: All machines and equipment are neatly painted; equipment cleaning schedule developed and posted for each major piece of equipment. Workbench and desk control: Kept free of objects including records and documents (unless in use). Tools and fixtures are clean and placed in their proper location. Information boards: PPB, COBs, and PABs are arranged in a neat and orderly manner. No outdated, torn, or soiled documents are displayed Emergency access: Fire hoses and emergency equipment are unobstructed and stored in a prominent easyto-locate area with proper identification. E-Stop switches and breakers are marked or color-coded for immediate visibility. Aisle ways marking: Aisles and walkways are clearly marked and can be identified at a glance; lines are straight and at right angles where appropriate with no chipped, worn floor marking. Equipment maintenance: Controls of machines are properly labeled. Critical points for daily maintenance checks are clearly marked. Equipment check sheets are clean, neatly displayed and completed daily. Tool and gauges convenience: Tools, gages and fixtures are arranged so they can be easily accessed when needed. Shelves and benches arrangement: Arranged, divided and clearly labeled it is obvious where things are stored; status and condition is recorded Document control: All documents are labeled clearly as to content and responsibility for control and revision. Obsolete Equipment cleanliness: All machines and equipment are kept clean by routine daily care. Floor cleaning: All floors are clean and free of debris, oil and dirt. Cleaning of floors is done routinely -- daily at a minimumposted schedule. 5S control and maintenance: There is a disciplined system of control and it is maintained at the highest possible level. It is the responsibility of every one to maintain this system and environment. Documentation exist indicating cleaning responsibility for each team member in the work area.

0 0

Straighten

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
5S Implementation Audit Score =

Shine Standardize Sustain

Necessary information is visible All standards are known and visible Checklists exist for all cleaning and TPM maintenance jobs All quantities and limits are easily recognizable All necessary items can be located in 30 seconds

All team members have had 5S training Daily 5S actions performed Place all personal belongings stored in a neatly maintained location Job aids are current and readily accessible Routine 5S Implementation Audit is performed until sustained

Legend: <2 (RED)

2 to 4.75

>4.75 (GREEN)

0.00

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It is important that we establish the first 3S before we progress to the next 2S.
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4S Standardize

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SHITSUKE = Self Discipline

Activity Success Indicator

- 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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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

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5S Sustain

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January 2007

June 2007

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Now, what would you do?

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Remember
1S 2S 3S 4S 5S Sort

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ASSESSMENT
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1 8 . 8 Wastes 9 11. 3 Different types of workplaces

12. It define difference between what is vs. what might be needed.

14. Organizing
15. Cleaning up 16. The core of 5S 17 20. Give 4 advantages of an organized and clean environment.
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