5s basic training ppt
TRANSCRIPT
House Keeping5S
Jayant Karandikar
Principle Consultant Qimpro
5S BASIC TRAINING
What is 5S and why do we want to do it?
What is 5S and why do we want to do it?
5S is short for: Sort, Set in Order, Shine, Standardize and Sustain
5S represents 5 disciplines for maintaining a visual workplace (visual controls and information systems).
These are foundational to Kaizen (continuous improvement) and a manufacturing strategy based "Lean Manufacturing" (waste removing) concepts.
5S is one of the activities that will help ensure our company’s survival.
5S
1. Sort Seiri- All unneeded tools, parts and supplies are removed from the area
2. Set in Order Seiton- A place for everything and everything is in its place 3. Shine Seiso- The area is cleaned as the work is performed 4. Standardize Seiketsu- Cleaning and identification methods are consistently applied 5. Sustain Shitsuke- 5S is a habit and is continually improved Also - Work areas are safe and free of hazardous or
dangerous conditions
Some New Words
Red Tag-Process for tagging, removing and disposing of items not needed in the work area.
Lean Manufacturing-concepts that seek continuous improvement by removing waste in processes
Some Japanese words you need to know: Kaizen-(pronounced “ki zen”) - improvement
Kaizen Event and 5S Event-Planned improvements to a
specific area or process (usually take 3 to 5 days).
5S Events focus on making 5S improvements.
Muda-(pronounced “moo da”) - waste
Gemba-(pronounced “gim ba”) - workplace
New Words - Continued
Kanban-(pronounced “kon bon”) - Pull type inventory control system. Items are only produced to meet customer needs. The request to produce more is signaled from an upstream operation and/or customer orders.
Value Stream Map - A diagram of all processes needed to make and deliver the product to the customer.
OTHER PROBLEM SOLVING TOOLS
TOC-Short for Theory of Constraints. Problem solving and constraint management methods. Use the 5 Step form of TOC to solve problems that you will encounter in your continuous improvement efforts.
The current situation
Space is crowded with parts and tools Unneeded items are stacked between workers Excess inventory on the floor Excess items and machines make it difficult to
improve process flow Equipment is dirty and a collection point for
miscellaneous materials Needed equipment such as tools are difficult to
find
Some 5S Examples
Before 5S
After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)
5S Examples - Sort, Set in Order
See the difference?
1. Sort - All unneeded tools, parts and supplies are removed from the area
2. Set in Order - A place for everything and everything is in its place
Dispositioning Items
Ideas for using 5S Tags and dispositioning items during the Sort phase:
• . • .
– .
No 5S TagUsed at least once every two days. Do not remove the item from its place of use
5S Tag, Type AUsed about once a week. Remove it from the direct work area but store it close to the work area.
5S Tag, Type BUsed once a month. Store it somewhere accessible in the facility
5S Tag, Type CUsed once a year or less frequently. Consider storing it outside or moving it off-site
5S Tag, Type DNo longer needed. Remove: sell, return, donate, or discard.
5S Examples - Shine
3. Shine - The area is cleaned as the work is performed (best) and\or there is a routine to keep the work area clean.
5S Examples - Standardize
4. Standardize - Cleaning and identification methods are consistently applied
Departments have weekly 5S tours
Every job has duties that use Sort, Set in Order and Shine
We all have common duties to do our part to keep all areas of the plant in shape - breakroom, restrooms, locker area, parking lot, etc
5S Examples - Sustain
5. Sustain - 5S is a habit and is continually improved
5S is a simple concept with powerful results.
You will get additional information on 5S so that you will be well equipped.
Our experience is that the more we do 5S the better the work environment becomes: cleaner, safer, more organized, the work is easier, less confusion and less stress.
Use the 5S (work\home\play) - The more you use it the easier it becomes and life just gets better and better.
The Good, Bad and the Ugly
First the Bad and the Ugly - Life Without 5S
The Good
What is Waste (Muda)? Some of the main forms of waste are:
Overproduction
Waiting for materials, machines, or instruction
Transportation or movement
Excessive inventory
Inefficient machine processing and/or operation
Producing defects
Part or line changeover or machine setup
Inadequate housekeeping
Miscommunication or inadequate instruction
Improvement (Kaizen) Principles
Get rid of all old (false) assumptions. Don't look for excuses, look for ways to make it happen . . Don't worry about being perfect - even if you only get it half right “start NOW”! It does not cost money to do KAIZEN. If something is wrong “Fix it NOW”. Good ideas flow when the going gets tough. Ask "WHY" five times - get to the root cause. Look for wisdom from Ten people rather than one. Never stop doing KAIZEN.
Summary
5-S is for you.
Clean-up and organize your work area every day so that each new day is easier and safer than the day before
Share your input with your leaders so that the tools you need will be available to you, increasing your efficiency.
Volunteer to help with the 5S tours and 5S events.
Take a good look around...Imagine zero waste/zero confusion!
.
The 5S Flow Plan
Plan a course of action. Educate the work group. Assess the work are Initiate the 5S's. Measure the results. Maintain 5S activities. Deploy to other areas.
THE 5S's AND THE PLAN-DO-CHECK-ACT MODEL
P
DC
A
1. Plan a course of action
2. Educate work group3. Evaluate work area
5. Measure the results
6. Maintain 5S activity
4. Initiate 5S
Activity 1. Plan a Course of Action Step 1. Organize 5S-Related Materials Step 2. Coordinate Internal Activities and Services
Needed From Other Departments Step 3. Establish a Schedule Step 4. Selecting the 5S Team Step 5. Establish Visible Ways to Communicate 5S
Activities Step 6. Present Plan to Upper Management & Define
Individual Responsibilities Step 7. Review Your Plan
Activity 2. Educate the Work Group Step 1. Refer to Your Implementation Plan to Decide
When to Schedule Instruction Step 2. Schedule Work Groups for Instruction Step 3. Review the Material and Rehearse the
Presentation Step 4. Present the Lesson Plan
Activity 3. Evaluate the Work Area Step 1. Use the Following Tools to Aid Evaluation Step 2. Coordinate Area and Section Boundaries Step 3. Divide the Work Area Into Sections Step 4. Conduct 5S Appraisals
5S Assessment
Activity 4. Initiate the 5S's
Step 1. Sorting Step 2. Simplifying Access Step 3. Sweeping Step 4. Standardizing Step 5. Self-Discipline
Activity 5. Measuring Results
Step 1. Conduct a Post-Implementation Assessment
Step 2. Analyze Results of the Post-Implementation Assessment
Step 3. Benchmarking
Activity 6. Maintaining 5S Activities (Making 5S a Habit) Step 1. Setting Goals Step 2. Establishing Sops (Standard
Operating Procedures) Step 3. Adhering to the 5S Process
Schedule
Conclusion
Plan a course of action. Educate the work group. Evaluate work area. Initiate the 5S's. Measuring results. Maintaining 5S activities.