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5S Implementation - The first step to continuous improvement

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Implementing 5S results in obvious improvements within the application area, plus, or even more importantly, in the change of people’s attitude towards their work and towards what they are doing.
5S implementation is the first steps to increase the efficiency in your company and the base for the future improvements.

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5S Implementation - The first step to continuous improvement

  1. 1. SUSTAIN 5S SET IN ORDER SORT STANDARDIZE SHINE efficient an company to steps first The
  2. 2. WHAT DO WE OBTAIN WITH 5S? Implementing 5S results in obvious improvements within the application area, plus, or even more importantly, in the change of people’s attitude towards their work and towards what they are doing. It is impossible to start a 5S campaign with only one or two persons. It is necessary to have everybody involved. Each thing that has to be done is fairly simple. The difficulty consists in doing that thing on a regular basis. This calls for determination, perseverance and cooperation. But this combination, in turn, creates a new meaning to team identity, and a better climate in the company. It is important that we start by doing. How well the theory has been understood is not essential. THE THEORY DOES NOT PRODUCE RESULTS!!! Only action produces results! And this action has the power to change people’s attitudes! It has the power to transform them! Each part of the 5S-process is important. Each step has the power to ‘open' people’s eyes. The 5S-method is the best way to start eliminating wastage.
  3. 3. 1. Sorting the things that aren’t necessary (Sei-ri) Purpose Differentiate between what is necessary and what is not used, and ‘get rid' of the things you don’t need. Elimination of things which are not needed Goals Setting the criteria and using it to eliminate that which is not necessary. Practicing 'stratified' management to establish priorities. Be ready to tackle the causes of dust. Activities Elimination of that which is not necessary. Addressing the causes of dust. Kaizen and standardization. Principles Elimination of things which are not needed. Analyzing the causes of why those things are there.
  4. 4. SORTING 1. Identify – which are the things that are needed at the workplace and which are the old, useless ones 2. Discard the things which you don’t need, don’t keep useless things. 3. The objects which are used weekly are stored in cabinets. 4. The objects used every hour are stored near or on the machine. 5. Buy the cabinets etc., which you need for the proper storage of the tools
  5. 5. The main purpose of the first S in 5S is to clarify the situation, which implies eliminating the loss caused by moving the things and the waste of time arising when searching for a tool or material. The other S – Setting in order and Standardizing – develop the habit of discipline at the workplace, a habit which is crucial in the next stages of Lean implementation.
  6. 6. 2. Setting in order (organising) the necessary things (Sei-ton) Purpose Establishing a neat and simple location plan, so that you can always have what you need, in the quantity that you need and then when you need it. A well organized workplace → Straightening the things I need so that they are within reach Goals Neat appearance of the workplace. Efficient and simple location plan (including for quality and safety). Increasing the quality by eliminating the waste of time for searching various things. Activities Functional storage based on the questions who?, what?, where?, when?, why? and how? Allocation of place for each thing and for all things. Visual arrangement for easier identification of things and locations. Setting up an easy replacement method. Principles Functional storage and elimination of the need to search for things.
  7. 7. SET IN ORDER 1. Placing things at the right place, they can be found and used in due time 2. Identifying the workplace, the machines, the shelves 3. Establishing housekeeping rules.
  8. 8. 3. Shining (Sei-so) Purpose Eliminating garbage, dust and foreign things for a clean workplace. Cleanliness as a form of inspection. Goals A level of cleanliness suitable to your needs. Target, a clean workplace, without mess and without dust. Finding the small problems with the Cleanliness Inspection. Understanding the fact that cleanliness is being checked for. Activities Setting up the standard procedure for cleaning Arranging the cleaning utensils at every workplace Preventing mess by targeting its source. Checking the equipment and corrective actions. Principles Shining is for control, standstill and defects elimination.
  9. 9. SHINING 1. Spend at least 5 minutes daily to clean the work area. 2. Waste and scrap separation and removal. 3. Check that all tools and/or materials necessary at the workstation (established at the first 2 S) are at their place.
  10. 10. 4. Standardizing the work methods (Seiketsu) Purpose Keeping things organized and clean, even in personnel matters. Standardizing the rules. Goals Standards for maintaining 5S. Developing visual management, so that abnormalities are “brought to sight” Activities  Creating a system of visual inspection.  Early detection and action devices  Handbook for maintaining standardization.  Developing a Color code.  Training, so that the people respect the housekeeping rules independently. Principles Visual management and 5S standardization.
  11. 11. STANDARDIZING 1. Make a habit of keeping orderliness. Be strict. No deviation is permitted. Else, the people around you will think that everything is just something for the moment. 2. Follow the rules. If it is necessary, change them, but follow the rules. 3. Don’t go back to chaos.
  12. 12. 5. Sustaining (Shitsuke) Purpose Doing the right thing, a matter that goes without saying. Goals  Everybody’s involvement to developing good habits and following rules.  Communication and feedback, a daily routine. Activities  5 minutes of 5S activities in every shift.  Communication and feedback.  Individual responsibility.  Practicing good habits. Principles Forming a habit and creating workplace discipline.
  13. 13. SUSTAINING 1. Follow the rules and ask the others to follow them, i.e. cleaning at the end of every shift, orderliness on desks, etc. 2. Search continuously for ways of improvement 3. Redo the 5S cycle at la regular intervals (PDCA). You will surely find something that can be improved, at every cycle. 4. Establish weekly audits for compliance with 5S.
  14. 14. 5S Five Japanese words starting with the letter ‘S’. SEI-RI (Sorting) SEI-TON (Set in order) SEI-SO (Shining) SEI-KE-TSU (Standardizing) SHI-TSU-KE (Self Discipline) FIVE KEYS FOR WORKPLACE IMPROVEMENT
  15. 15. Japanese English What does it mean? Seiri Sort Removing things which are not needed Seiton Set in order A well organized workplace  Setting the things that I need in order, so that they are within reach Seiso Shine Cleaning and keeping cleanliness at the workplace Shitsuki Standardize Standardizing the rules. Training, so that people follow the housekeeping rules independently Seiketsu Sustain Keeping the level up so that things won’t return to chaos.
  16. 16. The 5S have been and still are around us and there is nothing new on them. It is just that, until now, they have been neglected. When we look around closely, we will see that there are many possibilities of improvement. When we look at why we need the 5S at our workplace, it becomes clear right away that there are many things which we do without thinking. 5S can help in everything we do. 5S are like a mirror which reflects our attitude and behavior pattern. Very often we ‘cover' our eyes and prefer to not ‘look' at what we are seeing. Many daily problems that we face could be easily solved if we paid more attention to the 5S. Not complying with 5S defines a lazy mind an a sloppy attitude. Before the management and the leading structures (heads of department, team leaders, etc.) go ahead and tell other persons that they must implement 5S, they have to think really good about whether they themselves understand the necessity of implementing 5S.
  18. 18. 6 Defects prevention (Error proof) 5 Stop the abnormalities (Stop the movement of defects) Visual inspection Warning when abnormalities occur (Build the alerts) Build standards at the workplace Transmit the standards Transmit the information 4 5S Organization of the workplace 3 2 Visual display 1 SAFETY
  19. 19. 5S and Workplace Safety Highlighting orderliness at the workplace But, what this really means is that special attention has to be paid to the ordinary things. Do you use the safety helmet and shoes? Are you careful with the things when you carry them? Are the pathways clearly marked? This small – apparently insignificant – things are the one that make a difference. This is why people have emphasized the importance of a tidy workplace. In addition to these things, the 5S are also important for personal safety and health, prevention of fire and accidents caused by oil spills, for preventing pollution and other things which are so harmful for human health and safety.
  20. 20. 5S and Efficiency A good professional takes care of the tools he works with. A good professional uses tools which are in perfect operating condition and he takes care of them (maintains them, verifies them, fixes them, etc). He does not waste time when he works. All tools are held in order, so that they can be easily picked up and used when needed.
  21. 21. 5S and Quality Today’s machines need a high degree of precision and cleanliness. A splash of dirt can cause a defection of the computer. Filings and burrs can cause benchmarks to mismatch. Dropping things on the assembly line can mean that faulty parts are put together with good parts, or could be sent to another customer. There are all kinds of major problems caused by apparently minor things, missing 5S. It is clear that the 5S are a prerequisite of quality, and this cannot be emphasized enough.
  22. 22. SUMARRY Sorting = removing all things which are not needed. Set in order = storing things the right way, with the most used objects placed near the machines. Shining = removing useless objects, waste and scrap, cleaning the mess. Standardizing = following the housekeeping, arrangement and cleaning rules and using these on a regular basis Sustaining = complying with the rules and finding ways for improvement.
  23. 23. Thank you! AVO LEAN CONSULTING www.avoleanconsulting.ro office@avoleanconsulting.ro Tel: +4-0788-786383