7ws elimination of waste - management training
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8/3/2019 7Ws Elimination of Waste - Management Training
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5/5/12
Whichfinger isimportant
?
S e l f
d i s c i p l i
n e
S e t i n
o r d e r
Shi
ne
S t a n d a r d
i z e
S o r
t
संकलन
सिुवधा
शिु चतव
सुि िशक
सू यवथ
SANKALAN
SUVIDHA
SUCHITWA
SUVYAVASTHI THA
SUSHIKSHI TH
1S
2S
3S
4S
5
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What is 5S ?
• An essential step required for Waste
Elimination• An integral step in Kaizen
• A required element to achieve Lean-
site Manufacturing.
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1SSort
2S
3S
4S 5
S
Set inorder
Shine
Standardi
ze
Self discipline
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Commitment
• If you are disciplined. :
– Rules will always be followed.
–
Laid down targets will be achieved. – Improvements will be promoted .
– The no. of defects will be reduced.
– The cost will not increase.
Your work area reflects yourpersonality.
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Advantages
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The Five Elements of 5S
•
Systematic Organization-Identifying what items are requiredand which are not.
•
Sorting Visual Placement- Itemsshould be easily retrievable, easy toget, and visual-easy to see.
•
Scrubbing Clean-Keep the area freefrom debris dirt oil items not
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rogress veEnhancements
•
Step 1 – Establish 5 S Implementation Team
•
Step 2 – Develop Specific Implementation Plan
•
Step 3
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Wastes
• Wastes are createdfrom
– Uncontrolled process
– Uncontrolled machines
– Uncontrolled inventory
–
Uncontrolled materials – Uncontrolled acts
– Uncontrolled thoughtsSo control is the key of wasteelimination
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9 Wastes
• Overproduction
• Delays (waiting time)
•
Transportation• Process
• Inventories
• Motions
• Defective products
•
Untapped Resources
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MUDA - the elimination of waste
• Waste is all around us.
• Like iceberg: Some of it is
visible, much of it is not.• Waste exists in many
forms –
•
waste materials by overordering,
• wrong ordering,
• obsolescence due to
unscheduled design changes
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Defects
• Defects:deviation fromspecification.
• Change fromQuality Controlto Quality
Assurance• QA: Efforts to
get the
process right,
Prevention
Pre ven tio
n
D e t e c t
i o n
QA is Prevention
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Over-Production
• Produce only the quantity required.
• This challenged the Economic Order
Quantity concept, which was builton
– acceptance of fixed ordering costs,
–
built around set-up times, – spread these fixed costs over large
batches.
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Waiting
• Time not being usedeffectively is a waste –
• we are incurring thecost of wages and allthe fixed costs of
– rent,
– rates,
– lighting and airconditioning
•
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Transporting
• Items being moved incur a cost
• Managing a factory with operationsspread apart is much more difficultthan when the subsequent stages areadjacent to one another.
• This can be seen as the primarymotive behind cellular manufacturing
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Movement
• People spending time moving aroundthe plant is equally wasteful.
– Time spend to fetch tools, drawing etc.
– Supervision
– Procuring spares from stores
•
Re design the plant layout andmaintain housekeeping so thateverything that is required aremaintained close to hand.
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Inappropriate Processing
• Re work, re process, reject
• Do only what is appropriate.
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Inventory
• Inventory need holding cost.
• Stock hides problems
•
Finding a problem is a good thing -now we can solve it, which wecouldn't until it came to light!
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Untapped & misusedresources
• Untapped Resources
• Misused Resources
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Some tips
• Clean up once you leave for the day.Make sure your trash isdisposed properly and is not a
hazard to others. This minimizes theamount of time needed to clean abigger mess.
• Try to maintain a clean work areathroughout the day. Take a fewminutes to sort out your paper work.
• Make sure that combustible and
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Some tips
• Make sure that all drawers andcabinet doors are closed properly.
This will prevent injury to yourself
and others.• Place tools in a safe and known area. That way you will be able to find it
again.• If you spot a spill, report it and make
sure its cleaned as soon as possible.
• If ou are not sure of the chemical
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• 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 KAIZENor 5S
• If something is wrong “Fix it Here&NOW”.
Improvement Principles
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Don’t be a weak link inour system
Do itDo it NowDo it RightNow