5simproveworkinglevel 124099481243 Phpapp02

5S Improve Working Level
Click to edit Master subtitle style By, Hendra Syahputra
Dynaplast Packaging Vietnam Co., Ltd
Are they happy?
Are they happy?
What's our customer impression to DPVN?
Are they happy?
UNILEVER AUDIT RESULT Q4 2008
Can We do It?
Yes, We Can Do It!!
MANY WAYS TO DO IT:

n n n n n n n
KAIZEN TPM (Total Preventive Maintenance) TQC/M (Total Quality Control/ Management) 5S 6 SIGMA GMP (Good Manufacturing Practice) etc
Seiri Seiton Seiso Seiketsu Shitsuke
Sort Set Shine Standardized Self Discipline
SNG LC SP XP SCH S SN SC SN SNG
5S Overview
T Clearly distinguish needed items from unneeded items and eliminate the latter
SOR
(IN ORDER)
SET
(DISCIPLINE)
Make a habit of maintaining established procedures
SUSTAIN
Keep needed items in the correct place to allow for easy and immediate retrieval
This is the condition we support when we maintain the first three Ss
Keep the workplace swept and clean
STANDARDIZE
D CLEANUP
SHIN
E
5S Focus
Material Manpow er
Machines Metho d
Ltd
Produ ct
Mone y Dynaplast Packaging Vietnam Co.,
Seiri (Sort)
Seiri is the sorting of items in the workplace Clearly distinguishing between - what is needed and to be kept - what is unneeded and to be discarded Removing from the workplace all items that are not needed for current production operation
Why Unnecessary Items Accumulated

Change in sales-production plan The excessive ordering The incorrect ordering The lack of quality control The lack of quantity control Improper storage locations and /or poor storage methods A poor receiving and issuing system Duplicated ordering or delivering Aged or obsolete machines and equipment Damage by improper handling The duplicated production and storage of paper Dynaplast Packaging Vietnam Co., work Ltd
Sort at Workplace
Req uired Actio n
Items having no value and easy to dispose
Strat ificat ion
Throw away immediately
Items Not Necessary
Items having some value for sale

Items having no value but their disposal is costly
Look for a buyer who offers the best price Work out a less costly and safe way for disposal
SORT
Items Necessary Dynaplast Packaging Vietnam Co., Ltd
Sort for Documents

Identify all documents in lockers and desks Check if it is necessary to store. Discard unnecessary documents. Classify documents in accordance with nature of work. Prepare filing standard for major, medium and minor classification.
Register numbers in accordance with the standard. Implement Visual Control 30-second pick out test
Red-Tag strategy
Means of implementing sort (organization) by labeling all unneeded items with red tag
Steps in Red Tag strategy

Step 1: Launch the red-tag project. Step 2: Identify red-tag targets. Step 3: Set red tag criteria. Step 4: Make the red tags. Step 5: Attach the red tags. Step 6: Evaluate the red-tag targets. Dynaplast Packaging Vietnam Co.,
Ltd
Red Tag Target

Inventory Factories (workshop) Raw materials, procured parts, processed parts, in-process inventory Assembly parts, semi-finished products, products Machines, equipment, jigs, tools, cutting bits, gauges, dies, carts, Conveyance tools, worktables, cabinets, desks, chairs, supplies Floors, walkways, operation areas, walls, shelves, warehouse Notices and circular notices, minutes of meetings, clerical reports and Bulletins, approval sheets, estimates, contracts, management materials, Clerical materials Copy machines, computers, fax machines, paper shredders, printers, Other office automation equipments Folders, binders, file cases, cabinets, lockers, file boxes, storage boxes, Desks, chairs Pencils, mechanical pencils, ballpoint pens, permanent markers, erasers, Rulers, scissors, tape, staplers, cutters, memo pads Vouchers, business cards, magazines, Newspapers, Drawings, pamphlets Equipment
Spaces
Documentation
Equipment
Offices
Supplies
Stationery supplies
Others
RED TAG
Category
1. 2. 3. 4. 5.
Red Tag
1.
Item name Manufacturing No. Quantity Reasons
6.
Equipment products Jigs and tools inventory Measuring Instruments Materials Parts Semi finished products
7. Finished 8. In process 9. Office products
Category
Value
5. Others
2. 3. 4.
Raw material In-process stock Semi-finished goods Products
Unit
1. 2. 3. 4.
Not needed Defective Scrap material Unknown item
Item name Quality
Disposal by: Disposal Method Todays date
Department / Division / Section Disposal Complete (Signature) Disposal Date
Reasons Date
Red-tag file Nbr
Key Success to Red Tag Strategy

n n n n
Teach the importance of the 5S. Be sure everyone understand what Sorting means. The company MD should lead the red tag promotion council. Have red tag attached by people who have no direct relationship to the target items. Establish and use 5S audits.
Steps in Seiri (Sort)
Demarcate the area of the workplace Perform a diagnosis of the workplace Take a physical stock of all the items actually observed in the workplace Validate the items of physical stock take purpose, usage, predictability, regularity and criticality
Seiton (Set)
Arranging needed items so that they are easy to use and labeling them to make their storage sites easily understood by anyone.
Set in Work Place

Strat ificat ion
Items frequently used
Must be placed near the point of use
Req uire d Acti on
Items Necessary
Items sometimes used
Can be placed farther away
Items not used at all but must be kept Dynaplast Packaging Vietnam Co., Ltd
Must be stored separately with clear identification
Set Principles

Follow the first-in-first-out (FIFO) method for storing items. Assign each item a dedicated location. All items and their locations should be indicated by systematic labeling. Place items so that they are visible to minimize search time. Place items so they can be reached or handled easily. Separate exclusive tools from common ones. Place frequently used tools near the user.
Sign board strategy

It is a method for clearly indicating n where (location), n what (item names), and n how many (quantity). Machine/Equipment indicators
Steps in Signboard strategy

Step 1: Determine the locations Step 2: Prepare the locations Step 3: Indicate the locations Step 4: Indicate item names Step 5: Indicate the amounts Step 6: Make Orderliness a habit
Amount Indicators
1 1
AA AA AA AA
123
125
127
129
Maximum inventory amount Minimum inventory amount
2
212 214 216
218
Steps in Seiton (Set)

Complete the SORT stage Prepare the final list of validated items to be made available at the workplace Prepare a blank draft of the workplace with essential equipment Plan an optimal layout of the workplace with all validated items Have it verified and endorsed by Industrial and Safety Engineers or others in authority Convert the layout to reality Provide visual guides, such as workplace maps, tools layout, drawings, etc
Consideration in Set
Presentat ion Visibility Reach Out Safety Productiv ity
Color-coded for Dies
Color-coded for Die storage
Tiger Marks
Signboard for Tools and Jigs
Tools kept closed at hand

Operator returns tool without having to step back or look
Tools for this machine only
SG tools only
Arranged in order of use
Orderliness for Brooms

Step 1 No hole Lean it against The wall Step 2 Small hole Slip the hole Over a hook Step 3 Larger hole Hang a ring on the hook Step 4 Very Larger hole Slip it between the two peg
(hole Dimension)
(hole Dimension) (hole Dimension)
Eliminating the Need to Check Manual for Standards

Before improvement Pressure gauge
10 0 5 0
After improvement Pressure gauge

10 0 5 0
Gauge reading checked against standards in manual
Gauge reading checked against standards indicated on gauge displays
Seiso (Shine)
Cleaning up the workplace completely so that there is
no dust on the floor, n no dirt on the machines and equipment.
n
Seiso (Shine)
n SHINE n Is
is an ongoing commitment
the central stage and most difficult stage to implement checking, inspecting and cleaning of all items according to standard operating procedures training of proper personnel a great deal of discipline on the part of personnel through audits and spot checks
n Involve
n Involve
n Demands n Assured
Steps in Seiso (Shine)

Complete the SET stage Establish fixed schedules for SHINE activities Check whether the SET order of items are in place Systematically and according to the procedures established, clean all the items Dust and tidy up the workplace Report immediately any Dynaplast Packaging Vietnam Co., discrepancies Ltd
Cleanliness means Inspection
Phase 1: Daily Cleanliness Making things clean Phase 2: Cleanliness Inspections Using your senses Phase 3: Cleanliness Maintenance Making improvement
Daily Cleanliness
Step 1: Determine Cleanliness targets Step 2: Determine Cleanliness assignment Step 3: Determine Cleanliness methods Step 4: Prepare Cleanliness tools Step 5: Implement Cleanliness
Cleanliness Inspections
Step 1: Determine Cleanliness inspections targets Step 2: Assign Cleanliness inspection jobs Step 3: Determine Cleanliness inspections methods Step 4: Implement Cleanliness inspection. Step 5: Implement Cleanliness maintenance.
Cleanliness Inspection Point
Cleanliness Inspection Checklist
Cleanliness Maintenance
Cleanliness Maintenance
Discovery of abnormality or defect
Instant Maintenance
Request for Maintenance
Seiketsu (Standardized Clean-up)

Maintain the workplace so that it is productive and comfortable by repeating Seiri - Seiton - Seiso (Sort - Set - Shine)
Steps in Seiketsu
Do the STANDARD stage along with the SHINE stage Prepare briefing and training materials Have all the personnel go through the same briefing and training Build in team-work and a common purpose Dynaplast Packaging Vietnam Co.,
Ltd
Three Levels of 3S Conditions

Sor ( prevent disposal t of unneeded
items ) Unneeded items accumulate everywhere
Se ( prevent disorderly t arrangement of

items ) No one knows exactly where to find things.
Shin ( prevent things e from getting dirty

) The workplace is dirty - and nobody cares Level before Standardized Cleanup Without the 3S Basic level of Standardized Cleanup Make the 3Ss a habit
Throw away unneeded items
Arrange things in an orderly fashion
Clean dirty places
Why throw these things away ? Because they are not needed
Why do 3S conditions deteriorate ?
Why sweep the floor ?
Because they tend to Because they get dirty revert to their previous level
Advanced level of Standardized Cleanup 3S conditions are easily maintained
Three Ways to Make 3S a Habit

n
Assign 3S responsibilities Integrate 3S duties into regular work duties
Check on 3S maintenance level

Shitsuke (Self Discipline)

Always following specified and standardized procedures Training people to follow good work habits and the strict observation of workplace rules.
Steps in Shitsuke
Continue to implement the SHINE and STANDARD stages stringently
Engage people to be involved creatively in the implementation of 5-S
Give them the ownership and

leadership
Ways to Develop Discipline

n n n
The Visual 5S Correcting Others Company Wide Promotion 5S Promotion Tools
So rt Sustain
Set
Standard
Shine
The Visual 5S
S o rt
Set
Signboard strategy Location indicators Item indicators Amount indicators Painting strategy Color coded orderliness Outlining orderliness
R e d T a g st ra te g y R e d
Sustain / Discipline
5S checklist 5S audit score sheet

Shine
Cleanliness checklist Cleanliness inspection checklist Maintenance cards Maintenance kanban

Standardized Cleanup t
Cleanup level a checklist g
i n v e Dynaplast n Ltd t
Packaging Vietnam Co.,
5S Checklist
Visual Control System
1 0
1 1
1 2
1 0
1 1
1 2
Cleaning Inspection Checklist
5S Introduction Steps
Step 1 Establish 5S promotion organization Step 2 Establish 5S promotion plan Step 3 Establish 5S campaign materials Step 4 In-house education Step 5 5S implementation Step 6 5S evaluation and follow-up Dynaplast Packaging Vietnam Co., Ltd
Key Points for 5S Success

n n
n n
Continued commitment and support by top management 5S starts with education and training, make explanations easy to understand There are no observers in 5S, everyone participates Repeat the 5S cycle in order to achieve a higher standard

5simproveworkinglevel 124099481243 Phpapp02

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

5simproveworkinglevel 124099481243 Phpapp02

Hochgeladen von

Copyright:

Verfügbare Formate

5S Improve Working Level

Click to edit Master subtitle style By, Hendra Syahputra

Dynaplast Packaging Vietnam Co., Ltd

Are they happy?

Dynaplast Packaging Vietnam Co., Ltd

Are they happy?

Dynaplast Packaging Vietnam Co., Ltd

What's our customer impression to DPVN?

Dynaplast Packaging Vietnam Co., Ltd

Dynaplast Packaging Vietnam Co., Ltd

Are they happy?

Dynaplast Packaging Vietnam Co., Ltd

UNILEVER AUDIT RESULT Q4 2008

Dynaplast Packaging Vietnam Co., Ltd

Dynaplast Packaging Vietnam Co., Ltd

Yes, We Can Do It!!

Dynaplast Packaging Vietnam Co., Ltd

MANY WAYS TO DO IT:

Seiri Seiton Seiso Seiketsu Shitsuke

Sort Set Shine Standardized Self Discipline

SNG LC SP XP SCH S SN SC SN SNG

Dynaplast Packaging Vietnam Co., Ltd

This is the condition we support when we maintain the first three Ss

Keep the workplace swept and clean

Dynaplast Packaging Vietnam Co., Ltd

Mone y Dynaplast Packaging Vietnam Co.,

Why Unnecessary Items Accumulated

Strat ificat ion

Throw away immediately

Items Not Necessary

Items having some value for sale

Sort for Documents

Dynaplast Packaging Vietnam Co., Ltd

Dynaplast Packaging Vietnam Co., Ltd

Steps in Red Tag strategy

Red Tag Target

Dynaplast Packaging Vietnam Co., Ltd

Item name Manufacturing No. Quantity Reasons

7. Finished 8. In process 9. Office products

Raw material In-process stock Semi-finished goods Products

Not needed Defective Scrap material Unknown item

Item name Quality

Disposal by: Disposal Method Todays date

Department / Division / Section Disposal Complete (Signature) Disposal Date

Red-tag file Nbr

Dynaplast Packaging Vietnam Co., Ltd

Key Success to Red Tag Strategy

Steps in Seiri (Sort)

Dynaplast Packaging Vietnam Co., Ltd

Set in Work Place

Must be placed near the point of use

Req uire d Acti on

Items sometimes used

Can be placed farther away

Must be stored separately with clear identification

Sign board strategy

Steps in Signboard strategy

Dynaplast Packaging Vietnam Co., Ltd

Steps in Seiton (Set)

Presentat ion Visibility Reach Out Safety Productiv ity

Dynaplast Packaging Vietnam Co., Ltd

Color-coded for Dies