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    by: Ganesh

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    1 : 5S Prepared by M.Ganesh Murugan 9715447621 1 MGM
    2 : Necessity of 5S SEIRI SEITON SEIKETSU SEISO SHITSUKE Workplace improvement 5S 2 MGM
    3 : The 5 Words 5S is a method that uses five Japanese words which start with the letter S 5S 3 MGM
    4 : 5 S 5 Steps to a Better Workplace 5S 4 MGM
    5 : The Purpose of 5S is to promote a safe and efficient work environment Not just a cleaning campaign, 5S is a way to set a new standard that we all agree on and help us get the discipline we need to maintain it. By Implementing the 5S Opportunity to improve the own workplace Team involvement & Problem solving opportunities appears. 5S gives visible and Motivating Results First step in the implementation of Lean Manufacturing, TPM an Kaizen. Why 5 S? 5S 5 MGM
    6 : Improved Safety No items on the floor Therefore fewer slips or falls Safety device in their right places Less dust Reasons to implement 5S 5S 6 MGM
    7 : Improved Safety Fewer break downs Fewer “strange ” errors from electronic systems Less wear from dust or grit in moving parts Reasons to implement 5S 5S 7 MGM
    8 : Improved Safety Fewer break downs Better work Environment A clean & well functioning workplace Fix the unsafe & cluttered work stations Reasons to implement 5S 5S 8 MGM
    9 : Improved Safety Fewer break downs Better work Environment Less Environmental Impact Leakages such as oil will easily be spotted Using less floor space may reduce energy consumption Reasons to implement 5S 5S 9 MGM
    10 : Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors Easy to do it right than wrong Safety guards placed properly Less clutter, fewer visual distractions& easy access to tools and materials Reasons to implement 5S 5S 10 MGM
    11 : Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier When you do 5S , you inspect the same Reasons to implement 5S 5S 11 MGM
    12 : Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier No searching Effective tools at the right place Reasons to implement 5S 5S 12 MGM
    13 : Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier No searching Higher morale Through teamwork and visible results Reasons to implement 5S 5S 13 MGM
    14 : Improved Safety Fewer break downs Better work Environment Less Environmental Impact Few human errors May find problems earlier No searching Higher morale Goodwill Helpfulness to create an impression. Reasons to implement 5S 5S 14 MGM
    15 : The 5 phases in 5S 5S 15 MGM
    16 : Step 1 - Sorting 5S Sorting is a team activity that will be carried out by the production an d maintenance personnel together Sorting has two purposes Remove unnecessary objects Reduce waste 16 MGM
    17 : Remove unnecessary Objects 5S Go through the whole plant Look for Materials Behind or under machines Rejects Forgotten materials 17 MGM
    18 : Remove unnecessary Objects 5S Go through the whole plant Look for Materials Tools Not in use Worn out or broken “Custom-made” tools (made of steel wire/tape/etc-Replace by real tools 18 MGM
    19 : Remove unnecessary Objects 5S Go through the whole plant Look for Materials Tools Spare parts Broken Surplus Inventory Spare parts for machines no longer in use 19 MGM
    20 : Remove unnecessary Objects 5S Go through the whole plant Look for Materials Tools Spare parts Out-of-date Documentation Instructions Binders Manuals 20 MGM
    21 : Remove unnecessary Objects 5S Go through the whole plant Look for Materials Tools Spare parts Out-of-date Documentation Bulletin board Outdated notices Irrelevant information 21 MGM
    22 : Remove unnecessary Objects 5S Go through the whole plant Look for Materials Tools Spare parts Out-of-date Documentation Bulletin board Other stuff Outdated computer hardware Packing Material Outdated protective equipment 22 MGM
    23 : Remove unnecessary Objects ? 5S Look at each object Ask yourself, Do we need it at all? If not – Discard it or sell it Ask yourself, Will we need it soon? If not – Put it in proper storage eg:- spare parts, etc. Is it working , but.. Too difficult to use In correct design Too time consuming to use Has a high risk for injury/quality? Not easy to accessible 23 MGM
    24 : Remove unnecessary Objects ? 5S Each item to be discarded or corrected is marked with a red tag 24 MGM
    25 : Waste elimination 5S The second purpose of sorting is to reduce waste and generate ideas for improvements We will try to identify every thing that is hindering us from working safely and efficiently 25 MGM
    26 : Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instrutions Do we have them? Are they up-to-date? Are they in use? If not – why not? 26 MGM
    27 : Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety What measures should we take to eliminate the risk of fire and accidents? Remove clutter Improve unsafe electrical installations Replace broken safety devices Repair broken components 27 MGM
    28 : Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety Environment What measures do we need to minimize or prevent damage to the environment? 28 MGM
    29 : Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Anything missing ? Anything not working properly ? Anything in need of improvement? 29 MGM
    30 : Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Inconvenient work positions Seat & work s/f’s at the right height Awkward angles for moving materials 30 MGM
    31 : Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Inconvenient work positions Deferred maintenance Temporary repairs/not properly secured Old equipments/technical errors 31 MGM
    32 : Waste elimination 5S Try to identify every thing that is hindering us from working safely and efficiently Work instructions Safety Environment Tools and equipment Inconvenient work positions Deferred maintenance Improvement Proposals Review prior suggestions 32 MGM
    33 : Waste elimination 5S All identified waste items are marked with an red tag Machine tagged with errors and improved suggestions 33 MGM
    34 : 5S Sort list 5S Every tag refers to a 5S Sort list Think break Do we have any examples of deferred maintenance in our plant? 34 MGM
    35 : Question yourself – Seiri 5S Do you find items scattered at your place? Are any items left in disorganized way? Are all item sorted and kept in designated place? Are tools and stationeries properly sorted and stored? 35 MGM
    36 : Step 2 – Set in Order 5S Every tag refers to a 5S Sort list 36 MGM
    37 : Missing letter ? 5S Every tag refers to a 5S Sort list 37 MGM
    38 : Why-set in order? 5S The purpose of Seiton – set in order is that everything that we regularly use should have a convenient placement Tools should be kept at the point of use No bending to pickup or move materials Alter flow paths to improve efficiency 38 MGM
    39 : Placement 5S 39 MGM
    40 : Efficient layout and color coding 5S Make a drawing of the current situation Brainstorm to find an optimal layout Agree the color code Mark the location(removable tapes preferred) of all objects Move the equipments if necessary 40 MGM
    41 : Question yourself – Seiton? 5S Are passages and storages clearly indicated? Commonly used tools & stationeries separated from the seldom used? Are containers, boxes, materials and fire extinguishers stocked up properly? Are there grooves, cracks or bumps on the floor which hinder work or safely? 41 MGM
    42 : Step 3 – Shiny clean 5S Next step in 5S is to carry out a Shiny clean event 42 MGM
    43 : Shiny clean 5S To keep your area clean on a continuing basis Clean all machines thorough Clean all equipments, fixtures, and tools Clean the floor, walls, cabinets, shelves etc. 43 MGM
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