5s training and implementation
TRANSCRIPT
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By George Murigi
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ObjectivesObjectives
To understand the importance of 5s to our Lean
initiatives.To know what the 5Ss are and know the key
benefits of each.
Identify and overcome the barriers toproductivity
To be able to participate in group and individual
5s activities.
Improve quality of work
Practice efficiency at all times.
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5S Introduction
5S Steps
ContentsContents
5S and TPM implementation
Syndicate exercise
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IntroductionIntroduction
TPM Pillars
E
Train
Autono
Focu
Plann
A
Sa
En
TPM
rlyEquipment
anagement
ing&Educatio
n
ousMainten
ance
sedImprovem
ent
edMaintenance
ministration
ety,Health,
ironmental
Quality
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Clearing (Sort)
Organising (Set)
IntroductionIntroduction
5S
Cleaning (Shine)
Standardising (Standardise)
Discipline (Sustain)
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5S is a system to reduce waste and optimize productivity through maintaining an orderly
workplace and using visual cues to achieve more consistent operational results.
Implementation of this method "cleans up" and organizes the workplace basically in its
existing configuration, and it is typically the first lean method which organizations implement.
The 5S pillars, Sort (Seiri), Set in Order (Seiton), Shine (Seiso), Standardize (Seiketsu), and
Sustain (Shitsuke), provide a methodology for organizing, cleaning, developing, and sustaining
a productive work environment. In the daily work of a company, routines that maintain
IntroductionIntroduction
organization an or er iness are essentia to a smoot an e icient ow o activities. T is ean
method encourages workers to improve their working conditions and helps them to learn to
reduce waste, unplanned downtime, and in-process inventory.
A typical 5S implementation would result in significant reductions in the square footage of
space needed for existing operations. It also would result in the organization of tools and
materials into labeled and color coded storage locations, as well as "kits" that contain just what
is needed to perform a task. 5S provides the foundation on which other lean methods, such as
TPM, cellular manufacturing, just-in-time production, and six sigma can be introduced.
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Sort. Sort, the first S, focuses on eliminating unnecessary items from the workplace
that are not needed for current production operations.
An effective visual method to identify these unneeded items is called "red tagging",
which involves evaluating the necessity of each item in a work area and dealing
with it appropriately. A red tag is placed on all items that are not important for
operations or that are not in the proper location or quantity. Once the red tag items
are identified, these items are then moved to a central holding area for subsequent
dis osal rec clin or reassi nment. Or anizations often find that sortin enables
The 5S Pillars
them to reclaim valuable floor space and eliminate such things as broken tools,scrap, and excess raw material.
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IntroductionIntroduction
Our Environmental (Generally)
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IntroductionIntroduction
Just across the Road...
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IntroductionIntroduction
Our Environmental (Generally)
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5S Steps5S Steps
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To do this you may need to develop a policy or fix
some rules, i.e.
Low priority items may be stored in a distant
place.
5S Steps5S Steps
Clearing
area.
The team should agree the rules and must stick to
them.
A red tag is affixed to each item that is put into the
Red Tag area.
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Stratify Strategy for Clearing (Seiri)
Separate necessary items
from unnecessary items and
discard unnecessary items.
Categorise items according
5S Steps5S Steps
,
importance, storage space
required or the place
requiring the item, for
Example, control the
categorised items
according to their type.
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Red Tag is one of the implementation plans for Sort
(seiri), part of the kaizen strategy of workplace
improvement.
A method of identifying potentially unneeded items
Red Tagging
n e wor area.
Ensures that no needed items are accidentally
disposed of.
Allows us to evaluate the usefulness of an item bysegregating it when we are unsure of its use.
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Define the necessity of the item in order to perform
the work required on a day to day basis.- If it isnt needed it should be disposed of.
Determine the fre uenc with which the item is
Red Tagging Aims
needed.- If its needed infrequently it can be stored away
from the work area.
Decide the quantity of the item required to performthe regular work.
- Excess items can be disposed or stored away.
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Sample
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Sample
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Example
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Example
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5S Steps5S Steps
After Clearing
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BeforeBefore After After
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a) Remove unnecessary items and dispose of them properly
b) Make work easier by eliminating obstacles
c) Reduce chance of being disturbed with unnecessary items
Benefits of Seiri (, sort)
d) Prevent accumulation of unnecessary items
e) Evaluate necessary items with regard to dept/cost/other
factors.
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5S Steps5S Steps
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Workplace organisation
to fix the layout of tools and equipment
everything should be readily available when
needed.
5S Steps5S Steps
Organising
Everything needed should be Easy to see, Easy
to retrieve, Easy to use, Easy to return.
4E Philosophy
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5S Steps5S Steps
Useful check points for a organised workplace:
1. Are tools divided into specialised use and regular
use items?
2. Is the number of tools required kept to a minimum?
3. Are pallets, waste bins, hoses always placed in the
Organising
4. Is anything stored around safety or fire fightingequipment?
5. Are positions of main corridors and aisles clearly
marked?6. Can you immediately and safely find the items you
need?
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5S Steps5S Steps
Organising (Examples)
5S Steps5S Steps
Visual indications to easily show
visibility of tools and equipment
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5S Steps5S Steps
Organising (One more Example)
Shadow boards for
tools
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5S Steps5S Steps
Organising (5S Cabinet - Example)
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5S Steps5S Steps
After Organising
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1) Arrange all necessary items in order so they can be
easily picked for use
2) Prevent loss and waste of time
Benefits ofBenefits of SeitonSeiton ((?? ))
a e easy o n an p c up necessary ems
4) Ensure first-come-first-serve basis
5) Make work flow smooth and easy
6) Can also be translated as "set in order"
5S Steps5S Steps
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5S Steps5S Steps
38
5S Steps5S Steps
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Cleaning sounds simple enough, but it
involves a host of activities:
removing from the workplace everything
that should not be there
5S Steps5S Steps
Cleaning
ma n a n ng every ng a s ou e
there) in the best possible condition by
constant checking and constant care
Ultimately then "cleaning is careful
checking"
5S Steps5S Steps
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Before After
5S Steps5S Steps
Cleaning
5S Steps5S Steps
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5S Steps5S Steps
Cleaning Before...
Leaks all over the floor and no name
indications of the equipment
5S Steps5S Steps
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5S Steps5S StepsAfter...
Pilot equipment
5S Steps5S Steps
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Dividing zones/dividing roles
Indicate the role each person is to play (area of
responsibility)
Responsibility maps and check lists are
5S Steps5S Steps
Cleaning How to do it ?
43
Implement cleaning by area/equipment
Careful and systematic cleaning of particular
areas and equipment will help spot potentialproblems
Not simply wipe off dust - Cleaning is
Inspection.
5S Steps5S Steps
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Implementing improvements
Speed up the cleaning process
Make difficult/dirty places easier to reach and
access. (DTAs)
5S Steps5S Steps
Cleaning How to do it ?
.
Defining rules for the team (Code of Conduct)
5S Steps5S Steps
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Introduce a plant slogan
Take 5 minutes for 5S
5S Steps5S Steps
Cleaning How to do it ?
Take the time to make it shine!!
5S Steps5S Steps
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pp
After Demarcating
Area of operation
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Machine reliability
- Easier to identify issues on clean machines,meaning they can be addressed sooner.
- Cleaning is a form of inspection.
Benefits of Shine
Equipment / Tools- Clean equipment functions more effectively.
- Easier to spot damage or wear on clean
equipment and tools than on dirty ones.
5S Steps5S Steps
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5S Steps5S Steps
5S Steps5S Steps
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The state that exists when the first 3 S's are
properly maintained.
make sure that clearing, organising and
cleaning are being maintained and incorporated
into everyday activities.
Standardising
identify, eliminate or take preventive action to
help prevent 3S conditions to deteriorate.
A never-ending activity!
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5S Steps5S Steps
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After StandardisingNote the exact numberof items piling up the
standard
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Defined as "making a habit of properly maintaining
correct procedures".
pp
Discipline
keep discipline?
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5S Steps5S Steps
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1. The workplace would become dirty and chaotic
again.
2. Unneeded items would soon begin piling up.
Discipline Lack of Discipline
3. People would neglect to wear their PPE and
eventually sustain an injury.
4. Equipment malfunction and defective products
5. Customers would become disgusted by our dirty
and disorganised factory.
5S Steps5S Steps
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1. Total team involvement and focus on the challenge is vital
2. Develop complete visual control to make maintaining the standards as
easy as possible Remember it's about working smarter notharder!
3. Use Fixed position photographs of before, during and after to display
your efforts.
Discipline Important Hints
4. Use specific audits to evaluate your 5S effectiveness
5S Steps5S Steps
B ildi th Di i li
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Building the Discipline
Provide activity boards
for performance follow up
5S Steps5S Steps
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Discipline Activity Board (Example)
Activity Board - 5S
TEAM
5S Progress
5S
VISION AUDIT SHEET
AUDIT PLAN ACTION
PLAN
TAGS
CONTROL
ACTION
PLAN
ACTION
PLAN
ACTION
PLAN
ACTION
PLAN
TAGS
CONTROL
TAGS
CONTROL
TAGS
CONTROL
TAGS
CONTROL
5S
MISSION
OBJECTIVES
LAY OUT
IMPLEMENTATION
PLAN
5s Radar Chart OPL
OPL
OPL
OPL
OPL
OPL
OPL
STANDARD
BENEFITS
OPL
OPL
BENEFITS BENEFITS BENEFITS BENEFITSTOTAL TAGS
PROGRESS
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Hints on 5S implementation
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Select a Pilot area for 5s
Document the current situation. Photograph Conduct a Risk Assessment
5S Hints to start up
Establish resources required Plan the approach and communicate
Share equally the responsibilities
Monitor via auditing Measure the benefits
Hints on 5S implementation
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5S Hints to start up
...
Improve!!
5S and TPM implementation
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10
12
Continuous
im rovements
Waste & loss
Programme
Training Autonomous
Maintenance
Safety &
p
0
2
4
6
Time
FactoryGoals Effective
Maintenance
Environment
TPM in
Administration
5 S5 S
5S and TPM implementation
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S
afetyandEn
Contin
uousImprov
EffectiveMaintenance
p
vir
on.
e.
A
utonomousMain
t.
TPMinAd
ministration
Training
5S implementation5S by Teams
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5S by Teams Using the sophisticated equipment supplied and the
materials (e.g.: radar, audit sheet, typical activity board,etc)
available be inventive, imaginative, resourceful in
demonstrating:
Clearing, Organising, Cleaning,
Standardising & Discipline(Seiri, Seiso, Seiton Seiketsu and Shitsuke)
Where: YOUR Syndicate Room
Important NoteImportant Note
Remember that 5s needs to be applied during the 2 weeks
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