1980

1. Quality Improvements JAPAN U.S.A INDIA 1980 1950 1960 1970

2. 1. 5S Principles • Elimination of waste • Every body is involved, Co-operative effort • Attack root cause • Human being is not infalliable

3. 2. Objectives • Improve housekeeping • Make every individual responsible for housekeeping • Beautify by simple means • Productivity improvement by saving time, space etc.

4. 3. 5S’s • Seiri- Sorting • Seiton - Systematic arrangement • Seiso - Cleaning Inspection while cleaning • Seiketsu- Standardization • Shitsuke- Self Discipline

5. 5S If we do not do 5S, we can’t do any other work efficiently. They are features which are common to all places and are the indicators of how well an organization is functioning.

6. SEIRI = Sorting Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items Activity Establish a criteria for eliminating unwanted items Eliminate unwanted items either by disposing them or by relocating them. Success Area saved or percentage of space available Indicator

7. SEIRI = Sorting Japanese Meaning : The Japanese meaning of “Seiri” is to straighten and contain. - Get rid of waste and put it in order according to rules OTHER JAPANESE MEANINGS - farmland cultivation, Make an orderly system and straighten

8. What is unnecessary Seiri = Sorting 1. Item is not needed 2. Item is needed however quantity in stock is more than what is needed for consumption in near future 3. Contingency Parts Critically decide the quantity of contingency parts to be retained and criteria for such parts

9. Organization Frequency of use Storage Method Throw them out *Things you have not used in the past one year LOW *Things you have used once in the last 6-12 months Store at distance OR Keep in store *Things you have used only once in the last 2-6 months Store it in central place in your zone AVERAGE *Things used more than once a month Store it in central place in your zone *Things used once a week Store near the workplace HIGH *Things used daily or hourly Store near the workplace

10. Identifying unnecessary Seiri = Sorting • 1. Parts & Work in Process (WIP) • Things fallen back behind the machine or rolled under it • Broken items inside the machine • Things under the racks/ platform • Extra WIP • Stock of rejected items • Items accumulated over period for rework • Material awaiting disposal decision • Material brought for some trial, still lying even after trial • Small qty of material no longer in use Contd..

11. Identifying unnecessary Seiri = Sorting • 2. Tools, Toolings, Measuring devices • Old jigs, tools not in use are lying • Modified tools, tooling for trial, are lying after trial • Worn out items like bushes, liners, toggles etc. lying • Broken tools, bits, etc. may be lying • Measuring equipment not required for the operation • being performed , is lying • 3. Contingency Parts • Many times storage place for contingency parts become • a last refuge for broken parts, surplus items and things • nobody is likely to use Contd..

12. Identifying unnecessary Seiri = Sorting • 4. Shelves and Lockers • Shelves and lockers tends to collect things that nobody • ever uses , like surplus, broken items etc. • 5. Passages and Corners • Dust, material not required seem to gather in corner • 6. Besides Pillars and under the stairs • These places tends to collect junk, spittoon etc. • 7. Walls and Bulletin Boards • Old out dated notices which have lost their relevance • Posters or bulletins on wall • Dust, remains of torn notices, cell tape pieces Contd..

13. Identifying unnecessary Seiri = Sorting • 8.Floor, Pits, Partitions • Defective parts • Protection caps, covers • Packing material • Hardware items , small items • Even tools, tooling • Items dropped on the floor are never picked • 9.Computer Hard Disk • Many unwanted, outdated, temporary files pile up

14. Improvement methods Seiri = Sorting 1. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system eg. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for system eg. How to perform Seiri (sorting) 3. Check List A check sheet is used to decide what sort of main system and sub system are necessary.

15. Dealing with papers Seiri = Sorting How to reduce papers on your table ? 1. Make a single pile of papers 2. Go through them and sort in following categories a) Immediate action b) Low priority c) Pending d) Reading material e) For information

16. Dealing with papers Seiri = Sorting How to reduce papers on your table ? 4 D Principle DO DELEGATE DELAY DUMP

17. SEITION = Systematic Arrangement Meaning To determine type of storage and layout that will ensure easy accessibility for everyone. Activity - Functional storage - Creating place for everything and putting everything in its place Success - Time saved in searching Indicator - Time saved in material handling

18. SEITION = Systematic Arrangement Japanese Meaning: Dictionary meaning of Seiton is “to be correctly prepared”and “to prepare correctly”. In short these means : (a) arrange correctly in accordance with the correct method of doing activities and (b) make thorough preparations so that activities can be done even if they occur abruptly

19. SEITION = Systematic Arrangement The main target areas for Seri-Seiton improvement are : Tool-setting and preparation operations, line balancing and process planning, parts supply to assembly line, peak time problems etc. Improvement Methods Kit Method / Assembly box method / Outside tool setting Cassettisation / Parallel operations / Changes in assignment method

20. Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide where things belong • Decide how things should be put away • Obey the Put away rules

21. Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide where things belong • - Standardize Nomenclature • - Determine an analytical method of storage • Decide how things should be put away • - Name & locations to everything. Label both item • and location • - Store material functionally • - Prevent mistakes with coding by shapes & colour • contd..

22. Seiton = Systematic Arrangement • How to achieve Systematic Arrangement ? • Decide how things should be put away • - Follow first in first out rule • - If two identical items are to be located, then store • them separately, colour code them. • Obey the rules • - Put the things back to their location after • their use

23. Seiton = Systematic Arrangement USE : 1 ) Signboards 2) Colour codes 3) Outline markings 4) Labels

24. Seiton = Systematic Arrangement Functional Storage

25. Seiton = Systematic Arrangement Usage Frequency • Store frequently used material • near the workplace and less • frequently at some distance • Heavy material should be stored • at lower levels/layers • Place directly on the material • handling device for ease of • handling Weight & Shape of the Material Functional Storage

26. Seiton = Systematic Arrangement • Same category of material may be • stored in one location. • Eg. Allen Screws, Oil Seals Category • All items required for an • operation may be stored in one • location. • Eg. Allen key, spanner etc hand • tools required for setting m/c Operation Wise Functional Storage

27. Seiton = Systematic Arrangement • Outlining and Placement Marks • - Mark boundaries of dept., aisles, Machines • - Follow straight line, right angle rule • - Nothing shall be kept outside the boundaries • Stands and shelves • - Keep only required number of stands and shelves • - Standardize height, size • - Provide casters where necessary so that it can be • moved

28. Seiton = Systematic Arrangement • Wires and Ducts • - Colour code • - When there are multiple connections - bundle the • wires, label them and make sure that they are in • straight line /right angle and firmly anchored • Machine-tools & Tools • - Put the tools in the order you need them • - Location of the tool should be such that it can be • put away with one hand • - Try to eliminate some hand tools by permanently • attaching it to the bolt head

29. Seiton = Systematic Arrangement • Blades, Dies, Other important consumables • - Store them in the protected place • - Maintain these things regularly by applying rust • preventive, oiling etc. • WIP- Work In Process • - Designate a place for each component/part • - Decide on how much quantity to be stored • - Ensure that there is no damage to good part • during transit, they do not get rusty and they are • not mislabeled

30. Seiton = Systematic Arrangement • Oils • - Reduce number of oils used (Standardize) • - Colour code for oil • - Safety aspects - fire prevention, pollution, leak, • spillage • Instrumentation & Measuring Devices • - Label them, show direction of flow

31. SEISO = Cleaning Meaning Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of Inspection Activity - Keep workplace spotlessly clean - Inspection while cleaning - Finding minor problems with cleaning inspection Success - Reduction in machine down time Indicator - Reduction in no. of accidents

32. SEISO = Cleaning Japanese Meaning : Dictionary meaning “to clean up” and “getting rid of dirt and unclean items” While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection

33. Seiso = Cleaning • Here cleaning means more than just keeping • things clean. Cleaning should be viewed as a • form of Visual Inspection • Preventive measures should be taken to tackle • problems of dust, grim, burrs, leakage etc. • Root cause of the problem should be identified • and it should be eliminated

34. Seiso = Cleaning Various Minor Defects = Trash = Dirt =Knocking = Loose parts = Leaks =Scattering =Skips =Curvature =Abrasion =Rust =Scratches =Eccentricity =Lurching =Abnormal =Vibration Movements =Abnormal =Heat =Abnormal Sounds smells =Faded colour =Hisses

35. Seiso = Cleaning • 5 Minutes Every day for cleaning • Devote 5 minutes everyday for cleaning your • work area • Participation of everyone is required • Attack hard to clean places regularly

36. Seiso = Cleaning Cleaning-Inspection points for most equipment Grime, clogging, dust balls, rust, leakage etc. Cleaning No oil, Low oil, leakage, filter clogging, dirty oil, dirty or bent oil lines, clogged drainage, oil spillage, worn& torn ports etc. Oils

37. Seiso = Cleaning Cleaning-Inspection points for most equipment Loose bolts, welding detachment, loose parts, vibration or bumping noise, friction Tightening Oil tanks, motors, heater, axles, control panels, washing/ cleaning water, bearing, wiring etc. Heat

38. Seiso = Cleaning Cleaning-Inspection points for most equipment Breakage, cracks, dent on sliding parts, handle has come off, broken switches, wire joints come off, wires are broken or crack, crack dial of various pre. gauges, meters etc. Breakage, Cracks

39. Seiso = Cleaning Function wise Cleaning check list of equipment Compressed Air lines, air valves, connections, meters, filters, reservoirs etc. Pneumatics Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc. Hydraulics

40. Seiso = Cleaning Function wise Cleaning check list of equipment Motor fan, fan belt, couplings, Joints, pulleys, chains, pump bearings etc. Mech & Power Train Electrical Control panel, lamps, light, switch, sensors, wiring, ducts, fuses etc.

41. Seiso = Cleaning Function wise Cleaning check list of equipment Tools, fixtures, gauges, dies, measuring instruments, etc. Toolings Equipment Specific Furnaces, rollers, chutes, CNC machines, etc.

42. SEIKETSU = Standardization Meaning Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure) Activity - Innovative visual management - Colour coding - Early detection of problem and early action Success Increase in 5S indicator Indicator

43. SEIKETSU = Standardization Japanese Meaning : Dictionary meaning “unsoiled things, purity and cleanliness” Clean manners , Clean cloths, clean politician It is the proof that 3 S’s are being faithfully carried out.

44. SEIKETSU = Standardization Tools used for analysis : MTTR MTBF OEE

45. Seiketsu = Standardization • Regularizing 5S activities so that • abnormalities are revealed • Make it easy for everyone to identify • the state of normal or abnormal • condition • For maintaining previous 3S, deploy • visual management

46. Seiketsu = Standardization • It has been estimated by scientific • study that 60% of all human activities • starts with sight • 5S is easy to do once.It is consistency • that is difficult. That is why Visual • Management is so important, so that • everybody will know that there is • some problem. Visual Management

47. Seiketsu = Standardization • What visual control communicates ? • It grabs one or more of our senses in • order to • Alert us to an abnormality • Help us recover quickly • Promote adherence and prevention • Enable successful self management

48. Seiketsu = Standardization • Some methods for visual communication • Colour coding • Use of Labels • Danger alerts • Indication where things should be put • Directional arrows/ marks • Transparent covers • Performance indicators

49. Seiketsu = Standardization • Some methods for visual communication • Labels • Precision management labels • Inspection labels • Temperature labels • Responsibility labels

50. Seiketsu = Standardization Points to remember in making visual c control tools 1. Make them easy to see from distance 2. Put the display on the things 3. Everyone can tell what is right and what is wrong 4. Anybody can follow them and make necessary corrections easily 5. Work place should look brighter & orderly