Presentation

Title: Creating World Class Organization through

5S & Visual Management

Presented on

2nd Feb 2015 @

3rd Annual Lean Conference, AMA, Ahmedabad

Creating World Class Organizations Through

5S & Visual Management

5S is a set of steps to create a more productive workshop

5 Step to reduce or eliminate waste

• Searching

• Waiting

• Wandering

• Wondering

• Delays

• Extras

• Waste/Scrap

8 Type of Waste Transportation

Motion

Waiting

Inventory

Over processing

Rejection

Over production

Human Potential

× Cleaning and janitorial work to satisfy management.

× Imposing standards at workplace.

× Silver bullet to productivity gains.

Foundation to achieve employee engagement , waste reduction, improve workflow, and safety.

Empower workforce.

There will not be immediate influx of ROI when you implement 5S, but it trickles down slowly, in different forms & ways.

“There is not an end, it’s a journey”

5S Pictures

5S Pictures

5S Pictures

s 1st

S - SEIRI

Sorting Out

1. Touch everything

2. Evaluate everything with a standard set of decision

making rules

3. Tag it

4. Set tagged items in tag area

5. Record all items in a Red tag Register

Remove all unessential items from the workplace

Tools

Red Tag Red Tag Register Red Tag Area

s 2nd

S - SEITON Systematic

Arrangement

• Identify a home for everything that will be easy to find and

put away (PEEP)

• List everything that’s left from sorting step

• Create a master list of everything include as much in

formation on it as possible

• Agree on a location for these items,

1. How to keep them,

2. How many to keep,

3. Use Visuals to locate them

2nd S: Set in Order

Examples of Seiton

s 3rd

S - SEISO Spic and Span

• Keep everything in top condition. So, when someone need

something, it's ready

• Designate areas of space to different person

• Remove unnecessary items

• Sweep & wipe down with tools

Shine

Example of Seiso

s 4th

S - SEIKETSU Standardization

• Take the pictures

• Create a map of that locates where everything is stored

• 5S team maintains a job list and schedule 5S activities

Establish Visuals for everyone to maintain the condition

Example of Seiketsu

s 5th S -

SHITSUKE Self Discipline/

Sustain

• Clear deliverables & communication

• Score Keeping

• Continuous improvement with cyclic mini-5S events

Tools:

• Training and Awareness of 5S

• Dedicated 5S team

• Clear 5S Map and Responsibilities/Ownership

You are setting the standards to what you must live by

5S Benefits to Customer & Employees

Customer

• Win customer confidence by bringing them to factory

• Delight the Customer

• Customers always expect lower price. 5S is one way to make it possible

• Faster Response to queries/ requests

• Improves on time delivery

• Higher demands are met

Employees

• Improve employee involvement

• Lower Absenteeism

• Build Employee pride

• Working smarter not harder

• Higher employee Satisfaction

5S Benefits – Improves, Reduces

Improves • Productivity

• Quality

• Process Reliability

• Work Standardization

• Work Culture

• Daily & Shift Start Times

• Simplified work Environment

• Profitability & Efficiency by reducing time wasted looking for tools and Equipment

• Safety

Reduces • Transportations

• Cost

• Machine Down time

• Changeover Time

• Lead Time

• Waste

• Inventory

• Rejects/ Rework

• Breakdowns

• Waste in materials, Space & Time

How to implement 5S

Define Scope

• Where?- Identify where exactly boundary starts and ends

• Who?- Define the 5S team and participants with the visuals

• What?- Define the 5S job responsibility with required resources?

• When?- Settle down a plan for 5S activities with target dates and checklist for routine

How to implement 5S

Define Scope

How to implement 5S ? Collect Baseline Data

• Use pictures of Before and After (Inside - outside, Above-under)

• Time Study

• Cost & Quality of Inventory

How to implement 5S

Spaghetti Diagram Floor Plan Usage

Use Data

5S - SEITON

5S-SEITON

5S - SEITON

Thank You