WELCOME

APPLYING

5-S TECHNIQUES
FOR IMPROVED WORK ENVIRONMENT

5-Ss are Basic in Establishing Norms for Effective Performance

5-S is a KAIZEN Technique to Ensure Incremental Improvement

For Workplace Management

Why Implement 5-S & What are the real benefits ?

a. Improves Productivity b. Helps in proper maintenance c. Improves Quality d. Improves Safety e. Reduces Costs f. Detects Inconsistency in Workplace

OTHER REASONS FOR IMPLEMENTING 5-S Develops a KAIZEN mindset. Build Teamwork Establishes Discipline Negligible Investment Generates Enthusiasm Implementation is Easy

Some Points on 5-S

If you cant do 5-S, you cant do other work. The company thats doing badly is doing the 5-S badly.

Moving from managing by results to managing by causes.

5-Ss are Crime Prevention. 5-Ss are management barometer.

If you can do 5-S, you can do anything.

Where 5-S is Applicable?

Every Where

DERIVED FROM THE FIRST LETTERS OF

EIRI EITON EISO

EIKETSU HITSUKE

WHEN DO WE KNOW ABOUT THEM ?

5-Ss are there for a very long time.

WHAT ARE THE MEANING OF 5-Ss ?

ORGANISE/ SORT

EIRI

Distinguishing between necessary and unnecessary and getting rid of what is not needed.

WHAT ARE THE MEANING OF 5-Ss ?

SYSTEMATISE/
NEATNESS/LAYOUT

EITON

Establishing a neat layout such that one can always get as much of what is needed, when needed.

WHAT ARE THE MEANING OF 5-Ss ?

CLEANING/ SHINE

EISO

Eliminate trash, filth and foreign matter to have a cleaner workplace. Cleaning

as a form of inspection.

WHAT ARE THE MEANING OF 5-Ss ?

STANDARDISATION & VISUALISATION

EIKETSU

Keeping everything organized neat and clean. Standards to maintain.

WHAT ARE THE MEANING OF 5-Ss ?

DISCIPLINE/ SUSTAIN

HITSUKE

Doing the right thing as a routine matter.

General Scenario in Bangladesh

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General Scenario in Bangladesh

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General Scenario in Bangladesh

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General Scenario in Bangladesh

General Scenario in Bangladesh

SEIRI

(Organise)

Objective: To reduce or eliminate workplace clutter thereby reducing space requirements, stock levels, and reducing working capital. Thereby improving productivity
Classify everything around you Separately store according to the classification Discard all obsolete and unwanted things Fix rules for disposal Implement preventive 5S

Understanding SEIRI (Reorganise)

ORGANISE/REORGANIZE THE WORKPLACE

There should be only items necessary to perform work at the workplace. Dispose/remove all unnecessary items.
Ensure that unnecessary do not enter the workplace.

Understanding SEIRI (Reorganise)

FOR THIS IT IS NECESSARY TO DECIDE WHAT IS NECESSARY & UNNECESSARY IN A WORKPLACE:

So suggest them.
AS A PREVENTIVE MEASURE IDENTIFY HOW UNNECESSARY ITEMS ENTERS TO THE WORKPLACE:

Organise procurement & stores.

IDENTIFY THE EXCESS QUANTITIES

How to do SEIRI ?
1. Decide the scope of operation (what workplaces, areas) and target to be achieved. 2. Get Ready. 3. Teach people to recognize what is unnecessary. 4. Quantity & access. 5. Perform management inspection and assessment.

Classification - Stratification Management

Things we dont use Things we dont use but want to have on hand just Discard Keep as contingency items in a separate store/record room

in case
Things we use on & off Things we use infrequently Things we use frequently Store somewhere far away Store in the workplace Keep at the workplace

Points to remember in classification

Items we do not use
Throw away Donate If difficult to get you may still keep Sell and generate cash Hazardous waste use appropriate disposal means Confidential items - shred

Three techniques to help Classification

The Red Tag Technique
The Yellow Tag Technique Or use your 5 human senses
Look Listen Feel Smell Taste

Red Tag Technique

Using a suitable type of red colour disposal notice
1. Train persons in red tagging 2. Apply the tags

APPLYING THE RED TAGS

Decide on the standard for red tagging Committee or Int. Audit Make the red tags - paper, self adhesive tape, plastic covers, round seals Do the tagging during a selected period Mark details Keep for exchange period

Get final approval for disposal or other action

Dispose Dont delay

Red Tag Technique -Look at ...

Stocks Facilities Locations Documents Machines Fittings Stationery Bank Accounts Others

You may discover

Defective items Dead stock Sleeping stock Excess materials Excess spares

If in doubt throw it out?

Or Use the yellow Tag technique

Yellow Tag technique

When you are not sure On a fixed day label and mark date If label items are used thereafter remove the label. Inspect after 6 months(or 1 year) - Which items still have labels If still not sure repeat inspection after one year.

Advanced SEIRI - Habitual

Make rules for disposal by time or quantity
notices on notice boards, stocks, newspapers, used items, calendars, directories etc.

Reduce stocks
Mark min. and max. stock levels, fixed qty bins for forms, reduce bought out stocks, increase deliveries, reduce inventory by calculating stock minutes

Reduce W-I-P

Purely by implementing SEIRI

Many companies have
Reduced space requirements
Given up plans for new storage buildings

Reduced the capital expenditure on cabinets etc.

Reduced overdrafts and borrowing Generated Money in sales of discarded items Made the factory look better Made the office more pleasant

SEIRI
Unnecessary Papers 12 Kg.

Necessary Papers 2.5 Kg.

BENEFITS OF SEIRI
- Saves Floor Space

- Helps to Get Rid of Obsolete Item

- Gives a Clear idea of Material in Stock - Prevent incidence of Unnecessary Buying - Better Utilization of Existing Material

Understanding SEITON (Neatness)

Keeping necessary things appropriately such that always available. easily available. (A place for everything & everything in place)
All necessary things will have a fixed determined space to keep known to everybody.

Understanding SEITON (Neatness)

In keeping things consider classification Ensure:

Neat Workplace Efficient Layout Safe Keeping Eliminate search Efficient utilization of space
As if you can find things blindfolded.

SEITION

Objectives are :
Reduce search, pick up and transport time Improve Productivity of time Reduce Personnel stress Improve quality of work life. Improve quality of products and services Prevention of defects. Improve safety

SEITON Slogan A place for

everything and everything in its place

Understanding SEITON (Neatness)

Ensure:

Everything has a name and location Easy to keep

Easy to takeout FIFO Park like setting 30 Second retrieval

Understanding SEITON (Neatness)?

Point to Remember
Jumble Orderly Curved paths

Straight paths

Things are put every which way, which means that space is used inefficiently and you cannot put as many there as you should be able to.

Things are put at right angles and along straight lines. Space is used most efficiently. Things are all facing the same way.

Every curve means a likely collision and breakage. Every curve is dangerous. Every curve means slowing down.

Straight lines are safe lines. Things move faster and more efficiently.

Understanding SEITON (Neatness)

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Remember

SEITON
should result in
Reduced or eliminated search time No mix up Workplace look neat and inviting No stress Can you find anything - a file, a tool, a document, a particular letter in a file, the correct switch etc. in just a couple of seconds?

BENEFITS OF SEITON

Materials Easily Available

Materials Easily Retrievable Lesser Production Downtime

Machine Breakdowns Handled Fast

Time Taken to Search Minimized

SEISO (Clean)
The objective of this step is to improve health of machinery and human beings by a process of cleaning that makes checking easier.Create an obsession with cleanliness and to inculcate the habit of cleaning by self.

 Develop a cleaning culture Prepare a cleaning responsibility map Prepare a cleaning responsibility schedule Have a systematic approach Have 3 or 5 minute cleaning

Understanding SEISO (Cleaning)

Cleaning means inspection. Remove dirt, dust, grime and foreign materials from the work palace. Keep the work place & equipment in a ready to use condition. Keep work place clean and tidy. Cleanliness is - Primary Maintenance - Primary to Quality Identify source of dirt and contain at the source such that the workplace or equipment remain clean and useable.

Understanding SEISO (Cleaning)

While cleaning remove rectify defects. Cleaning is a team work. Cleaning is every bodies job. Cleaning is a part of routine job. Cleaning is a frame of mind: attitude Create a pleasant environment.

Assign individual and responsibility in cleaning.

collective

Cleaning responsibility maps

Entire premises divided into zones
Each zone to have a person responsible including the CEO Give clear directions on the standards expected

Even if a janitorial service is used their work must be checked by the zone in charge

Cleaning responsibility schedule

Divide responsibility for daily tasks to people Display the schedule
May even give evaluation points

Cleaning in a Scientific Manner

What to clean? When to clean? In which order to clean? Who is responsible? How to clean? What tools to use? What materials to use? Storage of cleaning tools Cleaning is checking - use the 5 senses

The Original Condition policy

It is true that machines begin deteriorating from the moment they are installed or unpacked. But every effort must be made to bring the piece of equipment back to original condition every day.

Then lifetime will be prolonged and breakdowns

will be less.

Cleaning is Checking
Clean equipment will facilitate detection of abnormalities. Cleaning is not polishing etc to make the piece of equipment more beautiful it is to look after its health.

Corrode and paint - perfume without a bath.

GARBAGE BIN STRATEGY

Have many garbage bins
Have many waste paper baskets Locate at regular distances Have separate bins for different items Have lids Teach people to use them

5 Minute Cleaning 5 Minute 5S

Fixed time or ad-hoc time Bell or alarm or music Standardised procedure for checking Everyone must participate Rigidly applied even when on the phone or having visitors

Understanding SEISO (Cleaning)

Some Points
1. Look for accumulated mucks, clogging rust, leakage etc.

2. In case of lubricants is it up to the level ? Look for leakage, filter free clogging, damage, collection tray etc.
3. In case of a bolts: Is it properly tightened ? Loose parts, vibration, sound, shock absorber, getting heated etc.

Understanding SEISO (Cleaning)

4. Look into hydraulic tank, oil valves, filter, adjustment.
5. Look at motors, condition of fans, fan-belt, coupling, joints, plugs, chains, pumps etc.

6. Look at electrical items, panel conditions, safety lamp, bulb, switches etc.

Understanding SEISO (Cleaning)

7. 5-S Pledge

- I will not get things dirty.

- I will not spill. - I will not scatter things around.

- I will clean things right away.

- I will rewrite things that have gotten erased.

- I will tape up things that have come down.

SEIKETSU
(Standardization & Visual Management)
Standardize all three steps Standardize procedures Evaluate using checklist

Implement Good and

Bad stickers

Understanding SEIKETSU
(Standardization & Visual Management)
Maintain strict control over Seiri, Seiton, Seiso activities such that there is no deviation. Regularizing the 3-S activities so that abnormalities show up. Making deviations obvious with visual control (Sensory alertness and control) Anybody can spot an abnormality. Visualization demonstrate alertness. Making the rules easy to follow.

Understanding SEIKETSU
(Standardization & Visual Management)
Tools and methods for visual control - displays to help people avoid making operating errors - danger alerts - indications of where things should be put - equipment designations - cautions and operating reminders - preventive maintenance displays - instructions

Understanding SEIKETSU
(Standardization & Visual Management)
Standards on Right and Wrong- Make them easy to see from distance. - Put the displays on the things they are for. - Make them so that anyone can tell what is right and what is wrong.
- Make them so that anybody can use them easily and conveniently. - Make them so that anybody can follow them and make the necessary corrections easily. - Make them so that using them makes the workplace brighter and more orderly.

The purpose of standardization is to make sure that the entire organisation follows the same procedures the same rules, the same names, same sizes, shapes, and colours etc.. Standardization may even be extended to other areas.

Understanding SEIKETSU
(Standardization & Visual Management)
Visual Management - levels. - Precision Management level. - Temperature Levels. - Other relevant Levels.

- Okay Mark.
- Standard Inspection.

Understanding SEIKETSU
(Standardization & Visual Management)
- Lub. Oil. - Inspection Levels. - Responsibility Levels. - Zone Levels. - Position Mark.

Floor painting strategy

Working areas - green Aisles - orange Rest areas - blue Warehouses - Gray Types of lines and sizes Avoid right angles

Door opening lines

Storage space lines Traffic flow direction lines

Safety signs
Dont do signs
Must do signs

Warning signs - Tiger patterns

Safe way signs Different colours Prominently displayed

Fix item
Item identification Shelf indication Should be flexible

Position Marks
Waste paper baskets Garbage bins Tables and chairs Cupboards and other furniture Inspection points

Wire Management
Off the ground Neat and straight Colour coded

Storage of registers and files

File index displayed Colour code

Oblique lines
Easy to see, easy to get and easy to return Identification strips on registers and books

Homes for registers and books

Index labels (A, B, C) Tags for important pages

Owner
Review period Summary pages

Next location

Understanding SEIKETSU
(Standardization & Visual Management)
Ensure Safety

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SHITSUKE
(TRAIN & DISCIPLINE TO CULTIVATE SELF DISCIPLINE )
Make everyone committed to the programme Motivate through competitions Enforce discipline to inculcate self discipline Have a 5S Patrol Team

Rule observance campaigns

Games

Encourage preventive 5S

Understanding SHITSUKE
( Discipline )
- Discipline as a way of cleaning habits.

- Doing the right thing as a matter of course. - Following upon standardization & checklists. - Practice until you can do it unfailingly. - Rule Observance Campaign.

Important considerations in 5S
Silver bullet improvements or gradualist approach Management must start 5S first. If you can do 5Ss you can do anything 5S is a barometer that tells you how well a company is managed. Implementation of 5S will indicate total participation

5S will make the factory a sales tool.

5S to cleanse the heart

THE THREE TYPES OF WORKPLACES

3rd Class workplace
Where everyone messes the place and there is no one to clean up

2nd Class workplace

Where people mess up the place and office helpers, cleaners, janitorial services or servants clean up the place

1st Class workplace

Where everyone is disciplined and does not mess up and all participate in cleaning

3 PHASES OF IMPLEMENTATION
Active 5S Habitual 5S Preventive 5S

THE 5S CYCLE

SEIRI

SEITON SHITSUKE

SEIKETSU

SEISO

T h a nk Yo u