2. Objective of Presentation:-
1. To improve the organisation and working standards of the
work environment.
2. To create a work environment that supports safe working
practices, right first time quality and efficient, productive
working
1. To learn Definition & understanding of 5S.
2. To understand benefits of 5S.
3. Auditing System.
Purpose of 5S Implementation:-
3. Define 5S .
5S Terminology.
5S Benefits: Cost, Quality, Productivity etc.
The Concept of RED-TAG area.
Explain Each ‘S’ in detail for better understanding of 5S Concept.
Best practices to implement 5S ( Examples).
Color code standards .
5S checklist for audit.
Topics covered :-
4. Define 5S :-
“An organizational methodology originating in Japan that, when
implemented, reduces the waste of resources and space while increasing
operational efficiency.”
“ The 5S elements, translated into English, are Sort, Set in Order,
Shine, Standardize and Sustain and are applied in some companies'
efforts to achieve "lean manufacturing.”
5S is also the foundation for Continual Improvement (CI) and Lean
implementation
5. 5S Terminology :-
1. Sorting :- “ Separating the needed from the not-needed.”
2. Simplifying :- “A place for everything and everything in its place,
clean and ready to use.”
3. Systematic Cleaning :- “Cleaning for inspection.”
4. Standardizing :- “ Developing common methods for consistency.”
5. Sustaining :- “ Holding the gains and improving.”
6. The Benefits of the 5s System :-
Increases in Productivity : -
1. Reduces lead times thereby improving product delivery times
2. Reduces equipment downtime, maintenance and cycle time
3. Improves daily and shift startup times and reduces changeover time
4. Reduces the amount of time wasted
5. Searching for tools and equipment
Increases in Quality : -
1. Improves quality by reducing the amount of errors/defects.
2. Implements standardization thereby achieving output consistency .
3. The pleasantries of the simplified work environment increases employee moral.
Reduction in cost :-
1. Provides cost-savings by reducing inventory, storage fees and
space requirements
2. Improves safety thereby reducing the cost of worker injuries
3. Reduces the amount of scrap thereby reducing production cost
7. The Concept of Red Tag & its area :-
“ The red tag system is simply a communication tool used to identify items
that a person has flagged for removal from a work area. While the tagging
is most frequently done during kaizen events, it can be done at any time.”
Red Tags:-
1. Red tags come in a wide range of
shapes and sizes, but the most
commercially available red tags will
have a wire or elastic loop on
them to attach to the item.
2. The information you need on the red
tat, at a minimum, includes the
name of the tagger, the reason it was
tagged, and the date it will be
removed.
3. More information may also be
required, especially if the item is to be
moved
to a red tag area. The additional
information helps to catalog or sort
the equipment.
8. Red Tag Area:-
1. The red tag area is simply a storage location for red tagged items that is
segregated from the production areas.
2. It must be kept neat and orderly so the equipment available in it can be
quickly surveyed by anyone in need.
3. When a red tag area is well maintained, improvement teams will be more
likely to make use of the red tag area, as they will have a better chance of
finding something they need
9. The Red Tag Technique involves the following steps:-
1. Establish the rules for distinguishing between what is needed and what is not.
2. Identify needed and unneeded items and attach Red Tags to all potentially
unneeded items.
3. Write the specific reason for Red Tagging and sign and date each tag.
4. Remove Red Tag items and temporarily store them in an identified
holding area.
5. Sort through the Red Tag items; dispose of those which are truly superfluous.
Other items can be eliminated at an agreed interval when it is clear that
they have no use.
6. Ensure that all stakeholders agree.
Consider ways to improve the workplace so that unnecessary items do not accumulate.
The Red Tag Technique:-
10. Explain Each ‘S’ in detail for better understanding of 5S concept:-
Sort:-
Definition :-
"Sorting" means to sort through everything in each work area.
Keep only what is necessary.
Materials, tools, equipment and supplies that are not frequently used
should be moved to a separate, common storage area.
Items that are not used should be discarded or recycled.
Don't keep things around just because they might be used, someday.
1. Removes waste.
2. Safer work area.
3. Gains space.
4. Easier to visualize the process.
Why we do?
1. Start in one area, then sort through everything.
2. Discuss removal of items with all persons involved.
3. Use decontamination/ environmental/safety procedures.
How to do?
4. Items that cannot be removed immediately should be red tagged
11. Set in Order:-
Explain Each ‘S’ in detail for better understanding of 5S concept:-
Definition :-
The key principle in "5S Set In Order" is: a place for everything and everything in
its place, with everything properly identified , labeled & ready for use.
Arrange workplace for safety and efficiency:-
1. Identify key equipment and supplies
2. Determine location for each item
3. Outline locations and zones
4. Develop shadow boards, label items
5. Document layout, equipment, supplies
Why we do?
1. Visually shows what is required or is out of place.
2. More efficient to find items/ documents (silhouettes/ labels).
3. Saves time, not having to search for items.
4. Shorter travel distances.
1. Keep things used together -kept together.
2. Use labels, tape, floor markings, signs, shadow outlines.
3. Sharable items keep at central location (eliminate excess)
How to do?
12. Explain Each ‘S’ in detail for better understanding of 5S concept:-
Shine:-
Definition :-
Why we do?
How to do?
“To keep your area clean on a continuing basis.”
1. A clean workplace is indicative of a quality product and process.
2. Dust and dirt cause product contamination & potential health hazards.
3. A clean workplace helps to identify abnormal conditions.
Use a plant layout as a visual to identify individual responsibilities for Cleaning-
eliminates “no man’s land.”
13. Explain Each ‘S’ in detail for better understanding of 5S concept:-
Standardization:-
Definition :-
Why we do?
How to do?
“To maintain the workplace at a level which uncovers and makes problems obvious.
To constantly improve our plant by continuous assessment & actions.”
To build 5S’s into our every day process to maintain “neat” and “clean”.
1. Build into everyday routines and checklists.
2. Develop schedules and checklists.
14. Explain Each ‘S’ in detail for better understanding of 5S concept:-
Sustain:-
Definition :-
Why we do?
How to do?
On-going training and maintaining the established 5S standards.
To maintain our discipline, we need to practice and repeat until it becomes a way of life.
To sustain sorting, storage and shining activities every day.
1. Good habits are hard to break.
2. Commitment and discipline toward housekeeping is essential in taking
the first step in being World Class.
1. “Red Tag ” Technique
2. Before & After photographs
3. Improve Area by Area, each one totally
4. Clear Responsibilities
5. Daily Cross Department Tours
6. Schedule ALL Critical Customers to Visit
7. Regular Assessment.
5S Focusing Tools:-
17. Checklist for 5S Implementation :-
5S Workplace Organization
Levels of Achievement
Level 5:
Continuously
Improve
Needed items are routinely
reworked/ replaced as
needed to improve work area
performance
Needed items can be
retrieved within 30 seconds
and require a minimum
number of steps
Problem sources are
documented with solutions
defined and implemented
M ethods for housekeeping,
labeling, inspections, and
work place design are
continually improved and
shared externally as
applicable
Root causes have been eliminated and
improvement actions focus on developing
preventive methods
Level 4:
Focus on
Reliability
Needed items are routinely
assessed against business
needs to assure functionality
and fit
Needed items have been
minimized in number/ size and
are properly arranged for
retrieval and use
Daily inspection occurs to
assess area readiness,
potential problems are
identified and fixed
Agreements for labeling,
housekeeping, inspections,
and work place design are
consistently followed and
demonstrate area
performance improvement
Sources and frequency of problems are
documented as part of routine work, root
causes are identified, and corrective
action plans are developed
Level 3:
Make it
Visual
A list of needed items for the
work area has been
documented
Needed items have dedicated
locations and are properly
labeled with required
quantities
Visual controls for
equipment, files and supplies
have been established for the
work area
Work area agreements for
needed item labeling and
visual controls are posted
and followed by work team
Work team is routinely checking area to
maintain 5S agreements and posting
results
Level 2:
Focus on
Basics
Needed and not needed
items have been sorted and
not needed have been
removed from work area
Needed items have been
safely stored and organized
according to frequency of
use
Key work area items to be
checked are indentified and
documented
Work area agreements are
identified and documented
for needed item organization
and work area controls
5S level has been determined and posted
on the communication board
Level 1:
Just
Beginning
Needed and not needed
items are mixed throughout
the work area
Items are placed randomly
throughout the work place
Key work area items to be
checked during a sweep are
not identified
No work area agreements
exist
There is no measurement of 5S
performance
Sorting Simplifying Sweeping Standardizing Sustaining
18. Road-Map for 5S Implementation Project :-
Action to be required for 5S Implementation at any Organization:-
Identify 5S Champion or Leader to Lead 5S Implementation Project.
Formed a Cross-Functional Team for 5S Implementation Project .
Imparted Training to Team member for Effective execution of 5S Implementation Methodology.
Define the work area 5S boundaries
Assign work group members to their 5S areas
Install a 5S communication board
Determine 5S targets, activities, and schedule
Review/finalize plans with work group and site leadership.
Take work area photos before 5S Implementation Project Start.
Evaluate current 5S Level of Achievement.
Define Red-Tag Area .
Identify needed & not needed Equipment or Item & apply Red-Tag on it
Shift Red Tag Equipment or Item to Red-Tag area.
Implemented place for Everything & Everything in its place.( If required develop SOP)
Mark Gang-Way & Work area as floor marking according to color code & labeling on Equipments or
Items.
Implemented 3ed S-Shine & Develop Checklist .
Formed 5S Audit Team & Audit Schedule.
Started monthly 5S Implementation Project meeting & Appraisal for the best Area.
Formed & Implemented 5S reward & recognition Policy.
