intimate fashion 5s

To Have the Right Things In the Right PlaceMaking the Workplace Bright and Productive

Intimate’s 5S Vision

From Basics to Benchmarks

Intimate’s 5S Journey

5S @ Intimate

Our 5S journey started during mid 2000 after seeing our Srilanka factory “BODYLINE Pvt. Ltd “

Training program was conducted for all employees about 5S

Posters were put up at all strategic locations in the factory about 5S

A contest was launched to all the employees for designing a suitable logo for the 5S movement at Intimate Fashions

Seiri day was celebrated to launch the first step of 5S on 10th October , 2000

SEITON @ Intimate

SEISO @ Intimate

SEIKETSU @ Intimate

SHITSUKE @ Intimate

SEIRI @ Intimate

5S is a simple but highly effective set of techniques

5S methodology was developed in Japan

5S is the foundation for any continuous improvement

5S removes waste from work environment through

better workplace organization, standardization, visual

communication and general cleanliness

5S factories are so well organized that abnormal situations

will be readily apparent

What is 5S ?

What are the 5Ss ?

5Ss5Ss Japanese English Meaning

1 S SEIRI SORT Remove unwanted items

2 S SEITON SYSTEMATIC

ARRANGEMENT

A place for everything and everything in its place

3 S SEISO SPIC&SPAN Cleaning with inspection

4 S SEIKETSU STANDARDISE Establish Standards for first 3Ss

5 S SHITSUKE SELF DISCIPLINE

Sustain & improve the first 4Ss

SEIRI- SORT

Remove waste, scrap, unused, sub-standard, excess items from

the workplace

Change the mental model of “Do not throw it away-it might

come in useful some day”

An effective visual method to identify & remove these

unwanted items is called Red Tagging

Seiri is eliminating unnecessary items from the workplace.

Space is freed for better utilization. Ensures Safety

Remove unwanted items

All unwanted items to be removed and placed in a

specially demarcated area called red tag area.

Unwanted items to be tagged with a red tag slip

Red tag slip will describe the item, quantity and date of

tagging

This process is for evaluation of the red tagged items

Occasionally used items are moved to a more organized storage

location outside of the work area from where unwanted items are

discarded

Guidelines to be framed for red tagging to prevent loss of

useful items

Red Tagging

SEITON-SYSTEMATIC ARRANGEMENT

Keep the right things in the right place and replace them in their respective place after usage

Use proper visual identification indicators Make sure storage is safe, to protect the item being

stored and also to prevent people from harming themselves when storing and retrieving

Do not store heavy items at the top making storage cupboards unstable

Seiton is keeping the needed items (those remaining after Sort) in the correct place to allow for easy and quick retrieval.

A place for everything and everything in its place

Better Inventory management.

Reduces Search time.Easy and Quick retrieval.

SEISO-SPIC&SPAN

Spend at least 5 Minutes daily for cleaning

Use appropriate tools for cleaning

While Cleaning also inspect for damage,defects and potential problems

Clean the Hidden areas also

Cleaning without care can cause more damage

Inculcate the mindset “It is My Duty to Clean My Place”

Seiso is Keeping the work place clean and also inspecting while cleaning

Cleaning with meaning

Equipment life is improved.Future problems are proactively identified and corrected

SEIKETSU- STANDARDISE

Establish uniform standards and procedures for labeling,

colour codes, indicators and safety norms

Display visual signage and control wherever possible

Establish proper Checklists, Responsibility Lists and

Schedules

Seiketsu is developing standards & responsibilities for the first 3Ss

Increases Quality & Productivity. Mistakes are eliminated

Establish Standards for first 3Ss

SHITSUKE-SELF-DISCIPLINE

Provide continuous guidance and training

Conduct regular 5S audits , display the result

Analyze audit findings & act

Create Interest & Involvement thro’ publicity & competitions

Ensure everyone is committed to “5S is my Responsibility”

SHITSUKE is perhaps the toughest of the 5S’s

Shitsuke is to implement mechanisms that are required to ensure the first 4Ss

5S becomes a Habit

Sustain & improve the first 4Ss

Seiri day was inaugurated by H.E. Mr. Tetsuya Unno the Vice Consul at the Consulate General of Japan for South India

The Chief guest unveiled the 5S logo

Prizes were distributed to the winners of the logo contest. (4 prizes out of 65 entries)

Red tag areas demarcated in every department

Red tags printed and issued to every department

Seiri was done throughout the factory on that day and all the red tagged items were moved to a common red tag area for the factory

SEIRI Day @ Intimate

SEIRI Day @ Intimate

Red Tag

SEIRI on Notice Board

Locker area

Main Entrance

Pathway to Reception

Intimate Fashions (I) Pvt. LtdGuduvancherry – 603 202

Main Entrance


Pathway to Reception


Front Portico


Entrance to Office


Reception


Office Corridor


Way to Production Floor


Sewing Floor


Material Testing Lab


Facility Block


Canteen Service Counter


Landscaping


Toilet


Road to Loading Deck

Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202

Stationery Template


Visual Identification

Wrong placement


Key Listing


Staff Tracer Board


Labels for Switch & Lights


Medical Center


Finished Goods Packing Area


WIP (1,50,000 components/line)


5S TEAM FORMATION

5S REVIEW BOARD

CEO & HOD’s

5S CHAMPION

STANDARDIZATION

TEAM

TRAINING

TEAM

AUDIT

TEAM

PUBLICITY

TEAM

Team Leader Team Leader Team Leader Team Leader

Members Members Members Members

Review once in 2 mths

New team every year

Chosen from volunteers


5S Team’s Responsibilities

• Standardization TeamStandardization Team

– To introduce standards for the first 3SsTo introduce standards for the first 3Ss

• Training TeamTraining Team

– To provide continuous education to all employees on 5STo provide continuous education to all employees on 5S

• Audit TeamAudit Team

– To schedule and conduct 5S auditsTo schedule and conduct 5S audits

• Publicity TeamPublicity Team

– To innovatively find ways of creating interest & To innovatively find ways of creating interest &

involvement on 5S with our employeesinvolvement on 5S with our employees

– To spread the awareness on 5S in our societyTo spread the awareness on 5S in our society


Training for Bus,Van & Car Drivers


5S Audits in Floor


Audit Results - Department


Audit Results - Intimate


5S Corner


5S @ Home - Home Kit

Intimate Fashions(I) Pvt. LtdGuduvancherry – 603 202.

5S @ HOME – One of Our Employee’s Home

Intimate Fashions(I) Pvt Ltd.Guduvancherry -603 202

INTEROFFICE COMMUNICATION

PURCHASE DEPARTMENT

TO : DATE : FROM : REF NO : SUBJECT : Best regards,

Interoffice Memo – Approved Format

Other Documents standardized are • Business Correspondence Letter• Minutes of Meeting• Fax Communication


Meeting Room – Status Indicator


Tiger Lines


Electrical Switch panel


Air Conditioner Chiller Plant


Less Frequent

File Colour Codification

Department colour


Head Supervisor Production Mechanic

FINISHED GOODS Sewing Machine Operator

Colour Coding for Uniforms Pregnant


INTEROFFICE COMMUNICATION

PURCHASE DEPARTMENT

TO : DATE : FROM : REF NO : SUBJECT : Best regards,

Interoffice Memo – Approved Format

Other Documents standardized are • Business Correspondence Letter• Minutes of Meeting• Fax Communication


Meeting Room – Status Indicator


Tiger Lines


Electrical Switch panel


Air Conditioner Chiller Plant