A STRATEGY FOR PERFORMANCE EXCELLENCE

What is 5S and why do we want to do it?

Anyone who has recently opened or running organization has certainly had these thoughts: How can I improve efficiency, work organization, quality, safety and housekeeping and protect my investment at the same time?

5S ?
Based on Japanese words that begin with S, the 5S Philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality efficiency and safety.

WHY 5S ?

To eliminate the wastes that result from uncontrolled processes. To gain control on equipment, material & inventory placement and position. Apply Control Techniques to Eliminate Erosion of Improvements. Standardize Improvements for Maintenance of Critical Process Parameters.

The concept of 5S has been twisted and its real meaning and intention has been lost due to attempts to keep each element in English word to start with letter 'S', like the real Nippongo words (seiri, seiton, seiso, seiketsu, and shitsuke). Well, whoever deviced those equivalent English words did a good job,they're close, but the real interpretation is not exactly the correct one. For the benefit of the readers who would like to develop and establish their own understanding and applications, the following are the real meaning of each element in English: Japanese - English Translations -------- -------------------Seiri - Put things in order (remove what is not needed and keep what is needed) Seiton - Proper Arrangement (Place things in such a way that they can be easily reached whenever they are needed) Seiso - Clean (Keep things clean and polished; no trash or dirt in the workplace) Seiketsu - Purity (Maintain cleanliness after cleaning - perpetual cleaning) Shitsuke - Commitment (Actually this is not a part of '4S', but a typical teaching and attitude towards any undertaking to inspire pride and adherence to standards established for the four components)

We at LG follow T5S ,For excellence

T5S

5S
SORTING SYS. ARRANGEMENT SWEEPING

3R
RIGHT LOCATION RIGHT QUANTITY RIGHT CONTAINER

VISUAL MGT.
TROUBLE SHOOTING MORALE PROD. STATUS

SYSTEMS
SELF DISCIPLINE

The Five Elements of 5S

Self-Discipline/ControlEnsuring that Systematic Organization, Visual Placement & Cleanliness are maintained. Systematic ArrangementIdentifying what items are required and which are not.

Systems- Maintain and continually improve the previous improvements. Sorting- Items should be easily retrievable, easy to get, and visual-easy to see.

Sweeping-Keep the area free from debris, dirt, oil, items not needed.

3R & Visual Mgt.

3 RIGHTS
- Standardize how to put the materials - Where : Right location - What : Right component in the right container - How much : Right qty

1) Display a board to know about place & qty 2) Manage limited stock : limited height, qty(Max. / Min.) 3) Paste identification sticker 4) Standardize contationers (Size, Color, Contents etc.) 5) Arrange jigs & tools : Open type stand, Grouping, etc. 6) Mark the line the location, easy to find like as supermarket

VISUAL MANAGEMENT

- To catch line problems quickly -To minimize line loss

1) Lamp A) Calling lamp : to require components B) Trouble lamp : Asm line status & trouble C) Operating lamp : Machine operating D) Production lamp : Target & Result 2) Major process : focused control of main process 3) Rejection : Sticker, special location 4) Production control : Display production status A) Target & Result B) Idle time display

Image by stages / T5S

1st Stage
Very dirty with unnecessary so it takes long time to find necessary materials
Materials & Tools are not arranged and dirty Tools & Jigs are kept in closed cabinet There is much time loss to find needed material Materials dont have their own location No gangway marking or materials are on the gangway

2nd Stage
Necessary materials are arranged, and easy to use
Cleaning equipment is placed besides line No individual 5S map & check list but just do cleaning Tool & Jig box is opened and placed to use easily Sorting is done and unnecessary materials are arranged Loading height is managed under 1.5M (same as eye height) Location marking of working table & material stand is done No closed room and gangway has yellow marking If line trouble happens only directly responsible person can know

3rd Stage
Everyone can know right location and qty and every material has their own location
Clarified 5S rule(5S map, Time,Check list) check, appraisal are being done All materials are marked to know their exact qty name & location Materials in stock are stored in marked area and limited height is under controlled Production status is managed hourly and improvement action is being done about production loss partly Defected parts are identified and marked defection reason also

4th Stage
Easy to know line trouble and has improvement system
Cleaning is being done continuously with clarified rule Cleaning is being done invisible area also Covers are transparent and keep cleaning Every trolleys and bins are named & numbered, placed to use easily Standard working guide is placed and educated to operators Right location, right qty & right container is under management Everyone can know line trouble and next action is being done to solve immediately Production status is controlled hourly and problems are being analyzed & improved immediately

5th Stage
Controlled by CIM and T5S is habituated to all organizations
T5S(5S, 3 Right & Visual management) is habituated All the materials are arranged very well like same as supermarket and under management always CIM is established and managed Stock is controlled automatically without any special in charge Problem is being solved with permanent countermeasure and nothing happens the same problem again Production status and trend can be known immediately Stock variation can be known and under management Working speed is controlled by computer

5S
Systematic Sorting Arrangement
Sweep Self Systems Discipline

3 Rights
Right Location Right Quantity Right Container

Visual Management
Marking, Open control Production Status Problem Alarm

Sorting

Sorting The first S focuses on eliminating unnecessary items from

the workplace. An effective visual method to identify these unneeded items is called red tagging. A red tag is placed on all items not required to complete your job. These items are then moved to a central holding area. This process is for evaluation of the red tag items. Occasionally used items are moved to a more organized storage location outside of the work area while unneeded items are discarded. Sorting is an excellent way to free up valuable floor space and eliminate such things as broken tools, obsolete jigs and fixtures, scrap and excess raw material.

Systematic Arrangement

Systematic Arrangement is the second of the 5Ss and focuses on efficient

and effective storage methods. You must ask yourself these questions: 1. What do I need to do with my job? 2. Where should I locate this item? 3. How many of this item do I really need? Strategies for effective Set In Order are: painting floors, outlining work areas and locations, shadow boards, and modular shelving and cabinets for needed items such as trash cans, brooms, mop and buckets. Imagine how much time is wasted every day looking for a broom? The broom should have a specific location where all employees can find it.

"A place for everything and everything in its place."

Sweeping

Sweeping:Once you have eliminated the clutter and junk that has been clogging
your work areas and identified and located the necessary items, the next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary in order to sustain this improvement. Workers take pride in a clean and clutter-free work area and the Shine step will help create ownership in the equipment and facility. Workers will also begin to notice changes in equipment and facility location such as air, oil and coolant leaks, repeat contamination and vibration, broken, fatigue, breakage, and misalignment. These changes, if left unattended, could lead to equipment failure and loss of production. Both add up to impact your companys bottom line.

Systems

Systems / Standardize: Once the first three 5Ss have been implemented,
you should concentrate on standardizing best practice in your work area. Allow your employees to participate in the development of such standards. They are a valuable but often overlooked source of information regarding their work.

Self Discipline

Self Discipline: This is by far the most difficult S to implement and achieve.
Human nature is to resist change and more than a few organizations have found themselves with a dirty cluttered shop a few months following their attempt to implement 5S. The tendency is to return to the status quo and the comfort zone of the "old way" of doing things. Sustain focuses on defining a new status quo and standard of work place organization.Once fully implemented, the 5S process can increase morale, create positive impressions on customers, and increase efficiency and organization. Not only will employees feel better about where they work, the effect on continuous improvement can lead to less waste, better quality and faster lead times. Any of which will make your organization more profitable and competitive in the market place.

Benefits

Elimination of Waste
5 S Element Waste/ Improvement Item Deliverable

Systematic Arrangement Sorting

Elimination of finding. Reduction of part selection errors.

Reduced Costs Improved Quality Increased Product Options Reduced Costs Increased Safety Improved Quality Increased Product Options. Increased Safety Improved Quality Improved Quality Consistent Delivery Improved Safety

Elimination of finding. Elimination of nonconformances. Elimination of motion. Reduction of part selection errors. Increased safety. Preventive maintenance. Increased equipment knowledge. Increased equipment life. Higher morale. Clean environment. Increased visibility of nonconformances.

Sweeping Systems

Implementation Plan
5S Implementation Plan

Step 1 Establish 5 S Implementation Team

Step 2 Develop Specific Implementation Plan

Step 3 Develop Communication Plan

Step 4 Develop 5 S Training Plan

Step 5 Implement 5 S

Systematic Organization

Progressive Enhancements

Standardization

Visual Placement

Cleanliness

Step 6 Verification of Effectiveness

Bad and the Ugly

First the Bad and the Ugly - Life Without 5S

Some evidence of standardized work areas

Clear, shiny aisle ways Color coded areas Slogans, banners

No work-in-process ( WIP ) One-Piece Flow Standardized Work Sheets

Some 5S Examples

Before 5S

After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)

5S Examples - Sort, Set in Order

See the difference? 1. Sort - All unneeded tools, parts and supplies are removed from the area 2. Set in Order - A place for everything and everything is in its place

What is Waste ?
Some of the main forms of waste are: Overproduction Waiting for materials, machines, or instruction Transportation or movement Excessive inventory Inefficient machine processing and/or operation Producing defects Part or line changeover or machine setup Inadequate housekeeping Miscommunication or inadequate instruction

9 Waste Radar Chart

% of Waste Before 5S % of Waste After 5S
Tr a n sp o rt a to in

Pr o ce ss

70 50 40 30 20 10 60

O ve r p r odu c to in 100 90 80

Un t apped R e so u rce s

0 De a l ys

I n ve n t o ry

M is u se d R e so u rce s De f e c t ive P r odu c t

M o to in

Summary
5-S is for you. Clean-up and organize your work area every day so that each new day is easier and safer than the day before. Share your input with your leaders so that the tools you need will be available to you, increasing your efficiency. Volunteer to help with the 5S tours and 5S events. Take a good look around...Imagine zero waste/zero confusion.