md. imrul kaes - 5S 2013-4-17
-
Upload
imrul-kaes-likhon -
Category
Documents
-
view
221 -
download
0
Transcript of md. imrul kaes - 5S 2013-4-17
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
1/42
5S
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
2/42
5S is a method of creating a clean and orderly workplace
that exposes non value added activities and makes
abnormalities immediately visible.
When someone refers to 5S, theyre generally referring to 5
Japanese words those start with S. But, it would seem,
contrary to what many people assume the origins of 5Smay not be Japanese after all.
4/16/2013 2MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
3/42
This is a Japanese method of creating a highquality and highly productive environment or it isa systematic 5 step method of organizing yourwork place.
To reduce wasted effort
To reduce wasted time
To reduce money To enhance value of output
To improve employee moral and motivation
4/16/2013 3MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
4/42
History of 5S
In fact, Henry Fords CANDO program which stands forcleaning up, arranging, neatness, discipline, and ongoing
improvement seems to be the obvious precursor to what we
call 5S today. This actually seems very logical since the
Japanese studied Fords method shortly after the war
ended. But to be sure, the 5S were focused on in this course
and in most lean manufacturing situations is based on 5
Japanese words.
4/16/2013 4MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
5/42
They are:
Seiri (sort)which is commonly translated as sort
Seiton (set in order) which means to straighten
Seisou (shine) which means to sweep or shine
Seiketsu (standardize) which actually means tosanitize but is most commonly referred to as
standardize today Shitsuke (sustain) which means self discipline or
sustain
4/16/2013 MD. IMRUL KAES 5
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
6/42
1.Sort : Sort the first S, focuses on eliminatingunnecessary items from the work place that are notneeded for current production operations. An effectivevisual method to identify these unneeded items is called
redtagging,which involve the necessity of each itemin a work area and dealing with it appropriately. A redtag is placed on all items that are not important for alloperations or that is not in the proper place. Once thered tag items are identified, these items are then moved
to a central holding area for subsequent disposal,recycling and reassignment. Organizations often findthat sorting enables them to reclaim valuablefloor space and eliminate such things as broken
tools, scrap and excess raw materials.
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
7/42
YELLOW LABEL METHOD:
When you are not sure.
On a fixed day label the item and mark date.
If labeled items used there after, remove the label.
Inspect after a specific period of time - which items stillhave labels, then put red tags on them.
If still not sure repeat inspection after some specific
period of time. Dispose of (if possible convert to cash) all obsolete
items.
4/16/2013 7MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
8/42
4/16/2013 9MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
9/42
2. Set in order: Set in order can be defined as arrangingneeded items so that they are easy to find and put away. Set inorder can only be implemented once the first pillar Sort has
cleared the work area of unneeded items. Strategy for effectiveset in order include affixing labels to designate proper storagelocations.
every thing has a specific place
and every thing is in its place
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
10/42
Implement a sign board strategy so that any locationcould be found easily.
Implement a grid system in large factories, offices andwarehouses.
Implement a floor painting strategy where all aisles,storage spaces, traffic flow lines are marked.
Implement a danger marking system.
Label all switches, fans, machines, chair tables actually
every thing. Clearly mark places for all tools, trolleys, vehicles,
guides, folders, needles and other maintenance andmechanics related tools.
4/16/2013 11MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
11/42
GRID SYSTEM:
Every building to be named A, B, C etc.
Grid system in large factory buildings andoffice buildings.
Every room to be labeled.
Every location of the factory should be able tobe located without difficulty.
Label strategy from the entrance.
4/16/2013 12MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
12/42
FLOOR PAINTING STRATEGY:
Working areas - green.
Aisles orange.
Warehouses gray.
Door opening marks.
Traffic flow direction lines.
You can mark with tiger pattern any where youneed to watch your steps, uneven steps, slipperyplaces.
4/16/2013 13MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
13/42
SIGNBOARD STRATEGY:
Factory ,work place, line, process.
Large and clear signs.
Use colors to distinguish.
All machines identified by name and number.
All assets to have inventory number. All employees should have a name and unique ID
number.
4/16/2013 14MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
14/42
STORAGE OF RESISTERS AND FILES:
File index displayed.
Color code.
Oblique lines.
Easy to see, easy to get and easy to return.
Identification strips on registers and books.
Homes for registers and books.
Tags for important pages.
4/16/2013 15MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
15/42
VISUAL CONTROL:
By color, shape etc.
Something that hits you in the eye easily.
To easily locate things.
To detect automatically.
To easily see current situation.
To easily see current problem.
4/16/2013 16MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
16/42
SAFETY SIGN:
DONTDO signs. MUSTDO signs.
Warning signs,
Safe way signs. Different colors.
4/16/2013 17MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
17/42
PROPER-AXIS ALIGNMENT:
Every thing should be aligned along proper axis.
Notice boards, charts on walls, calendars, paintings etc.
Machines and furniture wherever possible.
Shoe racks etc.
Vehicle parking
Things on the table tops.
No one should be allowed to keep anything out ofalignment.
4/16/2013 18MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
18/42
4/16/2013 19MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
19/42
4/16/2013 21MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
20/42
4/16/2013 22MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
21/42
4/16/2013 23MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
22/42
4/16/2013 24MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
23/42
4/16/2013 25MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
24/42
3. Shine: Shine means sweeping floors, cleaning machineryand make sure everything in the floor stays clean.
Working in a clean environment enable workers to noticemalfunctions in equipments such as leaks. These changesif left unattended could lead to equipment failure and lossof production. Organizations provides tools for cleaning
before starting shine operations.
Example : Machineries dust off and maintained.
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
25/42
Introduce self cleaning culture.
Implement cleaning responsibility and schedule.
Prepare appropriate cleaning tools, methods and
materials. Implement a garbage bin strategy.
Introduce a daily 5s 5 minute system where everyone
participates in cleaning activities.
Investigate sources of dust and grime.
Use 5 human senses for checking while cleaning.
Dirt and dust prevention is better than always cleaning.
4/16/2013 27MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
26/42
CLEANING:
What to clean.
When to clean.
In which order to clean. Who is responsible.
How to clean.
What tools to use.
What materials to use. Storage of cleaning tools.
Teach people how to use them.
4/16/2013 28MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
27/42
5 minute cleaning:
Fixed or ad-hoc time.
Bell or alarm or music.
Procedure for checking.
Everyone must participate.
Rigidly applied even when on the phone orhaving visitors.
4/16/2013 29MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
28/42
THE 5S PLEDGE:
I will not get things dirty.
I will not spill. I will not scatter things around.
I will clean things right away.
I will make cleaning a habit.
I will appreciate people who maintains highstandard.
I will encourage people for preventive cleaning.
4/16/2013 30MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
29/42
4. Standardize: Once the first three S have beenimplemented, the next pillar is to standardized the bestpractices in the work floor. Standardize, the method toperform the first three pillars creates a consistent
approach with which tasks and procedures are done.
Standardization is the process to make sure that the entire
organization follows the same rules, same procedure, same
color code, same names, same philosophy.
4/16/2013 31MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
30/42
The two steps in the process are-
Assigning 5S job responsibilities.
Integrating 5S duties into regular work duties.
The second part of standardization is prevention preventing accumulation of unneeded items, preventing
equipments and floors from getting dirty.
4/16/2013 32MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
31/42
5. Sustain : Sustain is a habit of maintaining correctprocedure. Without sustain other four pillars will not last longer.Changing behavior of the people is very difficult and there is a
tendency among the people that they want to go back to oldmethod. Proper monitoring and corrective actions are requiredfor this pillar.
The success of 5S pillar depends on:
Proper training.Participation of all workers.Correct procedure to do a particular job.Managers commitment to carry on better procedure.
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
32/42
Create a 5s culture where everyone willingly
participate.
Motivate through inter departmental
competitions.
Organize a 5s petrol team.
Reward good practices.
Top management should regularly inspect.
4/16/2013 34MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
33/42
Precondition for sustain:Awareness: you and your employees need to understandwhat the five pillars are and how important to carry on these
things.
Time: you need to have and make enough time in your workschedule to perform 5s daily.
Structure: you need to have support for your efforts fromyour top management in terms of resources and otherfacilities.
4/16/2013 35MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
34/42
Procedure for implementing 5S: Form a 5S team.
Develop a plan for each S.
Publicly announce the program.
Provide training and education to employees.
Select a day from when everyone starts formally practicing
5S.
Evaluate the results of 5S.
Take corrective actions.
4/16/2013 36MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
35/42
The Benefits of 5S:
If you paint the floor and machines with light color andclean them regularly, it may decrease energy consumption
because in day time less light will be needed. Painting and cleaning make it easier for the worker to find
any leakage specially oil leakage.
Proper cleaning may reduce accident probability.
Proper cleaning may reduce considerable amount of
defects. Proper sort may increase the real usable space.
Proper set in order can reduce searching time.
4/16/2013 37MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
36/42
Where can 5S be applied?
In homes
In schools
In offices
In factories
In hospitals
In work sites
In fact any where.
4/16/2013 38MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
37/42
Purpose of 5S
Improving the image of the company:
5s improves the image of the company. When thebuyers see a company follows 5s activities, theygets an impression that such a beautifullymanaged company must be producing goods ofhigh quality and must be delivering thempromptly and they feel no doubt about it.
Subsequently, the orders they receive to-datewould increase and would even start newtransactions.
4/16/2013 39MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
38/42
Improving productivity and prompt delivery:
When fabrics, accessories, machine parts etc
are stored in a way that they could be taken
out easily, time wasted for searching them,
planning time, transaction time, working time
could be shortened and by that delays could
be prevented.
4/16/2013 40MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
39/42
Reducing stocks:
By sorting out (seiri) materials such as
unnecessary stocks could be reduced. Then
arrange them in an order (seiton) and prevent
collecting in excess.
4/16/2013 41MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
40/42
Cutting down cost:
The above mentioned improvements in
productivity, quality, reduction in stocks etc
connect through to reduce the cost. Then
attempts could be made on cutting down
expenses by taking measures to prevent water
and electricity leakage etc.
4/16/2013 42MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
41/42
Managing safety:
Passages to walk through safely and area wheresome work could be done are maintainedproperly. Materials garments parts are storedorderly in a way that they would not fall down.The floor is free of cut pieces etc. safe enoughthat nobody will slip and injure themselves. The
rules for needle controlling etc are followed. Byfollowing 5s, safety of the employees could bemaintained.
4/16/2013 43MD. IMRUL KAES
-
7/28/2019 md. imrul kaes - 5S 2013-4-17
42/42
Activating a system and improving morale:
To work in a neat and clean work place is a
comfortable feeling for anyone and when it isso, they become interested in work. Also byfollowing the 5s, relationships betweenpeople and team work becomes cheerful andthereby the work place would systemized andmorale would increase.