5S (Workplace Improvement)

Pakshal Shah (320)

7 Wastes

Defect / Correction Overproduction Waiting Not utilizing

employee talents Transportation / material movement Inventory

Motion Excessive processing

Introduction
Seiri Seiton Seiso Seiketsu Shitsuke

Benefits of 5S

A clean workplace facilitates change Problems stand out Space made available for more business Better product quality and safety
While Implementing 5S

Is 5S For You?
5S process is a means to improving organization and cleanliness

How is this important to the business?

Quality Employees Customer Safety Time

Types of Workplace Environments

Types of Workplaces:

Third Class Second Class First class

Workplace Environments
Third and Second Class Workplaces

Sort

Step 1: Clarify what is needed.

Step 2: Dispose of things that are not needed.

Step 3: With items that are needed, segregate into layers, according to frequency of use.

How to Begin?
Have participants list areas to apply First S.

Have participants list unnecessary items in the work area.

Jig Shelves Outdoor Spaces Floor Surfaces

Stock Tools Pallets

Use FlipCharts.

Shelves
Machines Fixtures Desks or chairs Documents

Red Tags
As soon as an unnecessary item is identified, it is marked with a red tag so that anybody can see clearly what needs to be eliminated or moved. Clarify standards for unnecessary items:

NO TAG for items to be used within the next month;

TAG ON for items not to be used within the next

Managing Red Tags

Keep in Mind:

Dont let people directly concerned attach them! Listen to no excuses! Be strict about it! Attach tags to any doubtful item! The number of tags indicates checking efficiency not failure

Evaluation and Action

Designation

Action

Defective Items Excess Stock Obsolete Stock

Eliminate Store Dispose

Straighten
Clearly mark and arrange everything neatly so what is needed can be easily found

Step 1: Decide place for storage

Step 2: Set up markings for storage location

Step 3: Mark items to be placed for storage

Step 4: Ingenuity to make maintenance easy

Storage Space Marking

How will you know if good organization is in place? Can anybody Immediately:

How to Straighten?

Location Markings Methods for Numbering Item Classification Markings Necessity of Markings

See where, what and how many? Take item out? Return item after use?

Storage Space Marking

Customer Responsiveness

Knowing where everything is stored will allow faster response time to customers

Never allow defective items, on-hold items, and test products to become mixed with regular production items

Visual Management

Floor Surface Parts and plastic boxes

Storage Planning
Use of visual controls to enable immediate recognition of abnormalities Plan storage areas for ease in returning items to their designated positions

Choice is Yours

Shine
Clean up personal and working environment so there are no areas untidy with dirt, oil, and other clutter.

Step 1: Conduct overall cleaning of facility Step 2: Maintain cleanliness Step 3: Improvement plans to prevent dirtiness Step 4: Efficiency plan for 3S improvement

Why Shine?
First Impressions. What would be the customers first impression of your facility? Customer Expectations.

Would you want to have surgery in a dirty hospital????

Deep Cleaning
Cleaning includes Inspecting too:

Faulty parts Hidden, broken gauges Loose nuts and bolts

Cracked housings
Lubricant levels

Shine Targets

Storage Areas

Warehouses, shelves jig & tool storage, etc.

Equipment

Machinery, material handling lifts, etc.

Aisles, windows, meeting rooms, top of cabinets, etc.

Surroundings

Use Flipcharts to create list of areas.

Management of Cleaning

Decide what must be cleaned, and how often it should be cleaned.

Schedule the cleaning, and assign a responsible person to the task.

Schedule the cleaning at the same time each day to establish a routine. Make sure that all cleaning tools are available.

Moving On
It is important that we establish the first 3S before we progress to the next 2S

Standardize
Maintain the conditions of the first 3.

Step 1: Move on to all workplace areas Step 2: Implement Best practices throughout the workplace

Step 3: Communicate procedures to all employees

Step 4: Establish and monitor goals

Audit

Clearing up Organizing Cleaning

Sustain
Adhere faithfully to the decisions that have been made.

Step 1: Recognize improvements

Step 2: Celebrate successes

Step 3: Set high standards then test yourself for conformance

The 5S program must be re-enforced.

January 2007

June 2007

Case Study: Orange County Choppers

5S Implementation in workplace. Why is Senior angry? Is this the correct method?

Before

After

Before

After

Before

After

First Class Workplace

Good Job!

Thank You
Q&A