5s For Productivity.....

                                    What is 5S ?

“A Systematic Method of organizing your workplace to Enhance the Productivity”

            5S is a methodology for organizing, cleaning, developing and sustaining a

 productive   work   environment.   The  methodology   originates  from a  Japanese

 housekeeping    idea named   because  of  the five  Japanese  words each beginning

 with the  letter “se” or “shi”. They are  “Se-iri”, “Se-iton”,  “Se-iso”, “Se-iketsu” 

 and “Shi-tsuke”.

            What are the 5S’s ?                            

                1. Sort

                               2.  Set in Order 

                                                                  

                               3.  Shine  

                                                                     

                               4.  Standardize

                               5.  Sustain

                             DEFINITIONS

§  Seiri (sort)

Distinguish the necessary things from the unnecessary and dispose of the unnecessary.

This is the   priority area.

§  Seiton (straighten)

 Arrange the necessary items in an orderly fashion so they are easily accessed and  selected for use.

§  Seiso (scrub)

Clean your workplace to keep floors and equipment tidy.

§  Seiketsu (standardize)

Continually maintain the order, neatness and cleanliness.

§  Shitsuke (sustain)

Do things spontaneously without being told. Train everyone in the workplace   to  follow good work  habits so that it is a matter of personal pride and self-respect.

          When applied to a factory, 5S can help you solve

             the following types of common problems:

• Space crowded with parts and tools
• Unneeded items stacked between workers
• Excess inventory on the floor
• Excess items and machines hinder process flow
• Equipment is dirty and not serviced regularly
• Needed equipment, such as tools, is difficult to find.

•    

   

                     What Can 5S Do?  

     

• Improve Employee Morale and Safety

- Reduce Work Stress, Worry & Work Related Accidents

•       Improve Targets and Deliveries

- Reduce & Organize Inventory

- Improve Productivity & Internal Conflicts

•      Opportunity to produce a Quality Product/Service

                  - Improve the Quality of Work and Delight Customers 

•      Reduce Working Capitol

             -  Reduce and Organize Inventory & Hidden Costs

(01)   Sort

§  Separate what is needed & what is not needed

§        Keep only the needed

§        Discard unnecessary items

How to Start ?

Step 1

  : Make clear standard for deciding

       what is necessary & not.

             Step 2

               : Maintain it daily.

             Step 3

               : Audit process .

     

(02) Set in Order

§  Neatly place & identify needed work items 

                               

§   Designate a place for every item

§   Mark locations, names, etc.

§   Always put things back in their designated spots

  (03)   Shine

Step 1: Get  rid of all that dirt .                                                        

                     (5 minute 5S)

Step 2:  Correct any thing discovered.

Step 3:  Pinpoint the root cause of dirt 

                     and cut it off at  the source.

Step 4:  Prepare a Cleaning Schedule.

(04)  Standardize

§  Maintain & practice the first 3 S’s

§  Everyone knows their responsibilities

    Keeping things organized, neat & clean even in personal   and environment aspects.

          Activities :

§  5S Displays Boards

§  Zone Markings

§  Directional Markings

§  Color Coding

§  Labels

§  Audits/Audit Sheets

§  5S Manual 

(05)  Sustain

§ Become a role model for adhering to the standards of the 4 S’s

§       Make Rules & Procedures to promote a 4S

 Activities :

§ “All-together” cleaning

§  Individual Responsibility

§  5S Policy

§  Seeing is believing

5S Road Map

             Phase 1 – Prepare The Project 

             Phase 2 – Perform a Scan

             Phase 3 – Sort Through and Sort Out

             Phase 4 – Set Things in Order & Set Limits

             Phase 5 – Shine & Inspect Through Cleaning

             Phase 6 – Standardize Conditions

             Phase 7 – Sustain & Gain