About 5S implementation in Company? how to improve workplace.

1. Lean Manufacturing
PRESENT BY :
PRAVIN N PRAJAPATI

2. Lean Manufacturing..
 "lean” is a systematic method for the elimination of waste within a
manufacturing system.
 Simply Lean Means..
Creating more value for customer with fewer resources.
 The Ultimate goal is to provide perfect value to customer through a
perfect value creation process that has zero waste.

3. List of lean tool….
 5S
 Andon
 Bottleneck Analysis
 Continuous Flow
 Gemba (The Real Place)
 Heijunka (Level Scheduling)
 Hoshin Kanri (Policy Deployment)
 Jidoka (Autonomation)
 Just-In-Time (JIT)
 Kaizen (Continuous Improvement)
 Kanban (Pull System)
 KPIs (Key Performance Indicators)
 Muda (Waste)
 Overall Equipment Effectiveness (OEE)
 PDCA (Plan, Do, Check, Act)
 Poka-Yoke (Error Proofing)
 Root Cause Analysis
 Single-Minute Exchange of Dies (SMED)
 Six Big Losses
 SMART Goals
 Standardized Work
 Takt Time
 Total Productive Maintenance (TPM)
 Value Stream Mapping
 Visual Factory

4. Types of Waste or Muda
1. Overproduction
2. Inventory
3. Waiting
4. Motion
5. Transportation
6. Defects
7. Over processing

5. Reason for implement 5S
 Improved Safety
- No item on floor
- Safety device in their right place
- Less dust
- Better overview

6. Reason for implement 5S
 Improved Safety
 Fewer breakdown
- less dust from dust or grit in
moving part.
- fewer error

7. Reason for implement 5S
 Improved Safety
 Fewer breakdown
 Better work environment
- A clean work place
- Fix unsafe work place

8. Reason for implement 5S
 Improved Safety
 Fewer breakdown
 Better work environment
 Fewer human error
- Small but anything fault are fixed
- It should be easier to do right

9. Reason for implement 5S
 Improved Safety
 Fewer breakdown
 Better work environment
 Fewer human error
 May find problem earlier
- when you clean a machine you
inspect at same time

10. Reason for implement 5S
 Improved Safety
 Fewer breakdown
 Better work environment
 Fewer human error
 May find problem earlier
 No Searching
- Effective tools at the right
place

11. Indirect gains with 5S
 Practical training in lean for leaders &
Workers.
 Better impression in global market.
 Easier to recruit good people.

12. What is 5S ?
 The purpose of 5S is to promote a
safe & efficient work environment
 5S is a method that uses five Japanese
word which start with “S”
 Seiri – Sorting
 Seiton – Set in order
 Seiso – Shining (Clean)
 Seiketsu – Standardize
 Shitsuke – Sustain

13. Procedure…

14. 1S : Sorting
 Sorting has two main purpose
- Remove unnecessary objects
- Reduce waste
 Go through the whole plant
- Machine & Control centre
- Works area
- Storage and common area

15. 1S : Sorting
 Remove unnecessary objects
Look for..
 Material
- Behind or under machine
- Rejected
- “Forgotten” material

16. 1S : Sorting
 Remove unnecessary objects
Look for..
 Material
 Tool
- Not in use
- Worn out / Broken

17. 1S : Sorting
 Remove unnecessary objects
Look for..
 Material
 Tool
 Spare parts
- Broken
- Surplus inventory
- Spare part for machine
no longer in use

18. 1S : Sorting
 Remove unnecessary objects
Look for..
 Material
 Tool
 Spare parts
 Out of date document
- Files
- Manuals
- Computer temp. file
 Other Stuff

19. Red tag for 5S

20. 2S : Set in Order
 Arrange and mark the location of the all objects
 Organize remaining items

21. 2S : Set in order -- Placement
Item
Very rarely use
Long intervals between use
Frequently use
Can be placed outside
Work room
Placed Near the Machine Place closer to user location

22. Floor Marking
 Agree on a colour code
 Visualize
 Work Surface
 Safety Zones
 Machine Surface
 Transport surface

23. 3S : Seiso – Shine (Clean)
 Clean the workspace and all equipment, and keep
it clean tidy and organized.
 At the end of each shift, clean the work area and
be sure everything is restored to its place.
 Identify and eliminate causes of dirt and grime –
remove the need to clean
 Carry out regular cleanliness inspections.

24. 4S : Seiketsu - Standardize
 Simplify the way of maintaining cleanliness.
 Develop procedures, schedules, practices.
 Continue to assess the use and disposal of items.
 All employees doing the same job should be able to work in any
station with the same tools that are in the same location in every
station.

25. 4S : Seiketsu - Standardize
 Try to eliminate the problem.
 Implement daily routines
 Implement weekly procedure
 Use a planning system
 Planning Boards

26. 5S : Shitsuke - Sustain
 To maintain 5S, we need the discipline to practice
and repeat until 5S become a way of life.
 Visualization Board
 This is our area
 This is how it should look
 This is how we take care of our area.
 This is how we want to improve our area.
 This is how we make sure that the routines
are being followed.

27. 5S : Shitsuke - Sustain
Audits :
Schedule regular audits Ex.:
 Each Week – Team leader
 Each Month - Supervisor
 Every two month – Higher management

28. Thank You