5s - lean manufacturing methodology

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Presented By Dhaval Modi.

To make audience awareness about 5S’s.

How to use in our organization.

5s – A simple, but effective, lean manufacturingmethodology that helps organizations tosimplify, clean, and sustain a productive workenvironment

Originated in Japan

Based on the simple idea - clean and safe workenvironment

5s

Sort (Seiri)

Straighten -Set in order

(Seiton)

Shine (Seiso)

Standardize (Seiketsu)

Sustain (Shitsuke)

Sort focuses on eliminating unnecessary itemsfrom the workplace that are not needed forcurrent operations.

Ask yourself:

Does it have a function in this area?

Is it needed?

How often?

By whom?

Is it in the way?

Does it take too much space?

A red tag is placed on all items that are notimportant for operations or that are not in theproper location or quantity.

Once the red tag items are identified, theseitems are then moved to a central holding area(Red Tag Area) for subsequent disposal,recycling, or reassignment.

Set In Order focuses on creating efficient and effectivestorage methods to arrange items so that they are easyto use and to label them so that they are easy to findand put away.

Set in order- a place for everything, and everything inits place

identify best locations

Relocate out-of-place items

Set height and size limits

Focus on safety

install temporary location indicators

Shine is next step which imply thoroughly cleaning ofthe work area.

Working in a clean environment enables workers tonotice malfunctions in equipment such as leaks,vibrations, breakages, and misalignments. Thesechanges, if left unattended, could lead to equipmentfailure and loss of production.

Clean everything inside and out

Inspect through cleaning

Prevent dirt, grime, and contamination from occurring

Inspect equipment by cleaning

Standardize is the method to maintain the firstthree steps, creates a consistent approach withwhich tasks and procedures are done.

Standardize is prevention – preventingaccumulation of unneeded items, preventingprocedures from breaking down, andpreventing equipment and materials fromgetting dirty.

identified:

who is responsible?

What actions must be taken to maintain thedesired conditions?

When should those actions be taken?

Where do they apply?

What are the procedures for the applicationof standards?

Sustain, making a habit of properly maintainingcorrect procedures, is often the most difficult Sto implement and achieve.

Sustain focuses on defining a new standard ofwork place organization, Without the Sustainpillar the achievements of the other pillars willnot last long.

Tools far sustaining 5S include signs and posters,newsletters, pocket manuals, team andmanagement check-ins, performance reviews,and department tours.

Space is crowded with parts and tools.

Unnecessary items are stacked betweenworkers.

Excess inventory.

Excess items and machines make it difficult toimprove process flow.

Equipment is dirty and a collection point formiscellaneous materials.

Tools and equipment are difficult to find.

Practice the old slogan, “a place for everything andeverything in its place.”Place tools and instruction manuals close to thepoint of use.Design storage areas with a wide entrance and ashallow depth.Lay out the storage area along the wall to savespace.Place items so that they are easy to access.Store similar items together and different items inseparate rows.Do not stack items together. Use racks or shelveswhen possible.

Use small bins to organize small items.

Use color for quickly identifying items.

Clearly label items and storage areas to improvevisibility.

Use see-through/transparent covers and doorsfor visibility.

Remove unnecessary doors, walls, and otherbarriers to visibility, movement, and travel.

Use carts to organize, move, and store tools,jigs, measuring devices.

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