Qimpro Champion League: Challenge 1: 5S

(COLLEGE LAB)

INDIAN INSTITUTE OF FOREIGN TRADE (IIFT)

Pranjal Parihar

Vivek Maheshwa

ry

Anukriti Singh

WHAT IS 5S??? Name of the workplace organisation method

Identified as one of the techniques that enabled just in time manufacturing

5S stands for five Japanese words all starting with English letter ‘S’

Seiri (Sort)

Seiton (Set in Order)

Seiso (Shine)

Seiketsu (Standardize)

Shitsuke (Sustain)

ADVANTAGES OF 5S Reduce workflow problems.

increases product quality and productivity

Improve workplace safety

Align employee efforts with goals and strategies for eliminating waste.

1S. SORT

Separate necessary items

and the unnecessary items

and dispose unnecessary items

properly

2S. SET IN ORDER

Arranging all the items in a particular order for easy use

and reduce searching time for a

particular tool

3S. SHINECleaning the

workplace and maintaining its

appearance daily by establishing preventative measures to

produce on going cleanliness

4S. STANDARDIZE

Maintain and make the ‘sort’ ,’ set in order’ and ‘shine’

habitual. 5S becomes a part of

regular work

routine.

5S. SUSTAIN

Ongoing application of

knowledge , skills and abilities

gained from 5S process. Improving

organisational effectiveness.

5S

POOR 5S PRACTICES1. SORT

Necessary items are mixed with unnecessary items

Unnecessary items are lying in the work area

2. SET IN ORDER No differentiation between

necessary tools, equipment, etc.

Location of unnecessary items are not clearly defined

No Designated & permanent locations for items

3. SHINE The area is not cleaned thoroughly

Cleaning & inspection of areas are not taking place daily

4. SUSTAIN No proper SOPs are there;

There is no proper documentation of equipment & processes

No audit schedule is there

POOR 5S PRACTICES contd.

QUANTIFICTION OF THE PROBLEM

21%

16%

28%

35%

SET IN ORDERNot keeping the set up for experiments in order

Not arranginging students in group in a systematic order

Irregular sequence of experiments per-formed (theory lags behind pratical ses-sions)

Not keeping the equipemnts in proper place

Sort

47 hours Increase in time for conducting lab experiments (monthly) because of not following SORT. Above reasons causing the % of time occupied in SORT.

30 hours Increase in time for conducting lab experiments (monthly) by not following SET. Above reasons causing the % of time occupied in SET.

33%

51%

16%

SORT

Searching time for instruments

Seprating Necessary items from unnecessary items

Removing Un-ncessary items from work area

44%

26%

31%

Shine

Not wearing lab coats, goggles and gloves

No daily clean-ing of the floor

No regular cleaning of the working area

16 hours Increase in time for conducting lab experiments (monthly) because of not following SHINE. Above reasons causing the % of time occupied in SHINE.

QUANTIFICTION OF THE PROBLEM

12 hours Increase in time for conducting lab experiments (monthly) because of not following STANDARDIZE. Above reasons causing the % of time occupied in STANDARDIZE.

20%

27%33%

20%

STANDARDIZENot sticking quipment name on respective equipments

No proper SOPs

No full time lab assistants

No proper record keeping of the equipments

SUSTAIN: Because of above problems, approximately 105 hours are

wasted for conducting lab experiments (monthly). It does not add any value.

Using of 5S technique and continuously improving above, reduces this wastage time

Effective utilization of human resources can be increase by using this technique

QUANTIFICTION OF THE PROBLEM

RECOMMENDATIONS1. SORT

Establish a holding area for items (Red Tag area)

Identify items not required at the current location, if at all

Team members evaluate items in Red Tag area

2. SET IN ORDER Define the major processes (experiment) performed

For each process, draw a map of the locations of each activity

Identify sources of waste and corrective measures

Position items where they are needed based on frequency

3. SHINE Fix leaks & other problems

Inspect daily

Fix potential issues before they become major problems

4. STANDARDIZE Develop SOPs

Document equipment & processes

Develop audit schedule and assign tasks to individuals

Establish a methodology to ensure consistent strategy for 5S implementation

RECOMMENDATIONS

5. SUSTAIN Daily Checklist which looks at the cleaning of equipment and

floor, no unnecessary items, location and position of tools and storage, condition of storage area

Weekly/Fortnightly Audit of lab by Non-lab personnel formally check for things out of place, using same checklist

Lab In-charge: Taking Informal Walks through Lab to look for potential problems,

A Visual Board: To Show information about & results of 5S

RECOMMENDATIONS

How to quantify the general problem in the terms of time and cost

Advantages of 5S in industry perceptive

How to identify and separate the problems.

Good 5S Practices proves to be the best if they are brought in application.

Implementation of 5S technique in daily life .Better organize ourselves by like pasting stickers on books to differentiate them clearly in the rack, keeping our surroundings, room and study table clean etc.

Utilization of resources in a effective manner

How to use bar and pie chart for quantifying the problem

Help the students to face the competitive world in future.

Working in a team and sharing and exchanging ideas with team members.

LESSONS LEARNED BY THE TEAM

THANK YOU