5S Training for beginners. Presentation for the novice

5S Training for beginners. Presentation for the novice

1. 5 S – Workplace Management Presented by CMA Rahul Mench CMA Rahul Mench 9422416335

2. 5 S Goals Make everyone’s job easier Give all associates a high degree of ownership in their work, and pride in their workplace Increase communication by making information easier to understand Improve company overall success CMA Rahul Mench 9422416335

3. The Visual Management In the 5 S workplace, anyone will easily know the: who, what, when, where, why, and how within 5 minutes

4. Different types of workplaces There are basically three different types of workplaces: Third Class : People throw trash around and no one cleans up. Second Class: People throw trash around and someone else pick it up. First Class : No one throws trash around and everyone works to keep things clean. CMA Rahul Mench 9422416335

5. What is it? 5S is a workplace organization technique It is a way to involve associates in the ownership of their workspace It helps create and maintain the efficiency and effectiveness of a work area CMA Rahul Mench 9422416335

6. What’s in it for you? Cleaner work areas More organization Safer working conditions Less wasted time Efficient work processes and practices More available space CMA Rahul Mench 9422416335

7. The 5S Principles SEIRI :Sort out SEITON :Straighten/Set in Order SEISO :Shining SEIKETSU :STANDARDIZE SHITSUKE :Sustain CMA Rahul Mench 9422416335

8. Eliminate waste Sort Set in order Shine STANDARDIZE SUSTAIN CMA Rahul Mench 9422416335

9. Preparation for 5S Form 5S council for defining and controlling strategic implementation Form teams for Training, Promotion, Audit Divide total area of plant into small zones such that each zone will have 10 to 12 employees maximum. These employees along with their team leader will be responsible for 5S implementation. Display the list of zones, zone members and their team leaders at the respective location. Publish map of organization indicating all zones. Display boards showing demarcation of zones and zone identification. CMA Rahul Mench 9422416335

10. 5S VISION Clean, Safe and organized working environment for enhancement in quality, productivity, Safety and customer satisfaction. CMA Rahul Mench 9422416335

11. 5S POLICY We at, High Horse Power Diesel Loco Shed , Hubballi are committed to work together to inculcate healthy, clean, efficient and safe work culture. We will achieve this by practicing the principles of 5S namely sorting, Setting in order, Shining, standardization and sustaining. CMA Rahul Mench 9422416335

12. 5S OBJECTIVES To improve storage system To improve waste management To create more working space To improve retrieval time To create clean and safe work place Enhancing performance through continual improvements CMA Rahul Mench 9422416335

13. 5S PLEADGE I take this pledge that I will maintain my workplace in an organized manner by Disposing the unwanted materials periodically Placing required materials at their designated place Keeping my workplace neat , clean and safe Following the standards Sustaining this work culture CMA Rahul Mench 9422416335

14. 1- The First S - Sorting Separating the Needed from the Not-Needed Decide what you need. Remove unnecessary clutter. All tools, gauges, materials, classified and then stored. Remove items which are broken, unusable or only occasionally used. CMA Rahul Mench 9422416335

15. The First S - Sorting Red Tag Technique: GIVE STAFF RED LABELS ASK STAFF TO GO THROUGH EVERY ITEM IN THE WORK PLACE ASK IF NEEDED & THOSE THAT ARE NEEDED,IN WHAT QUANTITY NOT NEEDED >> RED TAG IT STORE IN THE RED TAG AREA RED TAG CMA Rahul Mench 9422416335

16. Red Tag CMA Rahul Mench 9422416335

17. The First S - Sorting Place the suspected items in the RED TAG AREA for one week. Allow the staff to re-evaluate the needed items. At the end of week those need items should be returned. CMA Rahul Mench 9422416335

18. Red Tag Log Sheet Enter details of all tags attached into Red Tag Register. Maintain such register into each 5S zone. CMA Rahul Mench 9422416335

19. The First S - Sorting Suggested Guideline Priority Frequency of use How to use Low Less than once per year Once per year Throw away Store away from the workplace Average Once per month Once per week Store together but offline High Once Per Day Locate at the workplace CMA Rahul Mench 9422416335

20. The First S - Sorting Expected Results of Sorting : Elimination of wastes of resources, material, spaces, …etc. Reduce WIP inventory CMA Rahul Mench 9422416335

21. 2- The Second S – Set in order A place for everything and everything in its place, clean and ready to use Organise layout of tools and equipment Designated locations Use tapes and labels Ensure everything is available as it is needed and at the “point of use” CMA Rahul Mench 9422416335

22. The Second S – Set in order Workplace Checkpoints:- Storage places clearly marked? Tools classified and stored by frequency of use? (Low, Average and high) Pallets stacked correctly? Safety equipment easily accessible? Floors in good condition? CMA Rahul Mench 9422416335

23. The Second S – Set in order Expected Results of Sorting : No more Searching. Reduce Setting up time Prevent : misplacing, Leaking oil, wasting energy or materials .. Etc. Improve: Space Utilization. Eliminate: Searching time Dangerous conditions CMA Rahul Mench 9422416335

24. Does this look well Straightened? CMA Rahul Mench 9422416335

25. Outlines or Footprints A little out of place CMA Rahul Mench 9422416335

26. A Place For Everything EVEN RAGS, GLOVES, AND TRASH CMA Rahul Mench 9422416335

27. A Place For Everything EVERY ITEM HAS A PLACE, IS LABELED, AND COLOR CODED CMA Rahul Mench 9422416335

28. 3- The Third S – Shining Cleaning for Inspection Identify and eliminate causes of dirt and grime – remove the need to clean. Sweep, dust, polish and paint. Divide areas into zones. Define responsibilities for cleaning. Tools and equipment must be owned by an individual. Focus on removing the need to clean. CMA Rahul Mench 9422416335

29. The Third S – Shining Expected Results of Sorting : Higher Quality work and products. More Comfortable and safer work environment. Greater visibility and retrieval time. Lower maintenance time. CMA Rahul Mench 9422416335

30. Before and After CMA Rahul Mench 9422416335

31. A well shined facility CMA Rahul Mench 9422416335

32. 4- The Fourth S - Standardizing Developing Common Methods for Consistency Generate a maintenance system for the first three Develop procedures, schedules, practices Define uniform color codes Continue to assess the use and disposal of items Regularly audit using checklists and measures of housekeeping Real challenge is to keep it clean CMA Rahul Mench 9422416335

33. 5S Checklist CMA Rahul Mench 9422416335

34. 5- The Fifth S - Sustaining Holding the Gains and Improving Determine 5S Level of Achievement Perform routine checks Analyze results of routine checks Measure progress and plan for continuous improvement CMA Rahul Mench 9422416335

35. Visual Ranges Make It Easier to Sustain CMA Rahul Mench 9422416335

36. Visual Ranges Make It Easier to Sustain CMA Rahul Mench 9422416335

37. Sustain EVERYONE NEEDS TO DO THEIR PART TO KEEP THINGS WHERE AND HOW THEY BELONG CMA Rahul Mench 9422416335

38. 5S Supportive Strategies Color coding Point of use Safety CMA Rahul Mench 9422416335

39. COLOR CODING THINGS IS A FAST, EASY WAY TO SEPARATE DIFFERENT ITEMS AND TO VISUALLY DETERMINE IF SOMETHING IS MISPLACED 1-Color Coding CMA Rahul Mench 9422416335

40. CMA Rahul Mench 9422416335

41. Examples CMA Rahul Mench 9422416335

42. Examples CMA Rahul Mench 9422416335

43. Color Coded Scrap Hoppers CMA Rahul Mench 9422416335

44. Part Color Coding Different color for each part number Colors correspond to colors of: work units tooling gages fixtures settings CMA Rahul Mench 9422416335

45. Color Coded Dies CMA Rahul Mench 9422416335

46. 2-Point of Use Tools Parts disposal Operating procedures Lock-out instructions Materials/Finished goods Information Looking For Tools

47. Point of Use (Shadow Board-Visual Control) CMA Rahul Mench 9422416335

48. Point of Use NOT ENOUGH ROOM TO STORE AT THE POINT OF USE, SO MAKE THEM MOBILE CMA Rahul Mench 9422416335

49. Point of Use FIXTURES ROTATE SO THEY TAKE UP LESS SPACE AND ARE KEPT AT THE POINT OF USE CMA Rahul Mench 9422416335

50. Point of use INFORMATION CMA Rahul Mench 9422416335

51. Safety: The 6th - S IS OF GREAT CONCERN WHEN CONSIDERING WORKPLACE ORGANIZATION AND THE 5S’S CMA Rahul Mench 9422416335

52. Safety (Visual Control Signage) COLOR CODED GUARDS AND LABELING CMA Rahul Mench 9422416335

53. Safety WELL LABELED, BUT WHAT KEEPS PEOPLE OUT OF COILS? CMA Rahul Mench 9422416335

54. Safety COLOR CODED AND VISUAL -EASILY ACCESSIBLE? CMA Rahul Mench 9422416335

55. Floor Labeling Example CMA Rahul Mench 9422416335

56. Signage is any kind of graphics created to display information. SIGNAGE Displays To make staff aware of related data and information – charts, graphs etc Controls To guide the action of staff members – sign boards, dos and don’ts signs CMA Rahul Mench 9422416335

57. Signs Example Designated Location CMA Rahul Mench 9422416335

58. The 5S numbers game. CMA Rahul Mench 9422416335

59. This sheet represents our current work place. Our job is to strike out the numbers 1 to 49 in correct sequence. Example: 1 2 3 Time : CMA Rahul Mench 9422416335

60. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 44 45 46 47 48 49 50 51 52 53 54 54 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 40 CMA Rahul Mench 9422416335

61. For our first action, we are going to implement 5S in this area. The first step of this is “Sort” and so we have removed from the area all the numbers from 50 to 90 which are not needed. Same rule apply. Strike out numbers 1 to 49 in sequence Time : CMA Rahul Mench 9422416335

62. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 44 45 46 47 48 49 40 18 CMA Rahul Mench 9422416335

63. Having achieved some improvement, we now need to move onto the next step ”Set In Order”. We have installed some racking, and we have organized the items so that with Number 1 in the bottom left hand corner, the numbers are located from left to right and bottom to top - examples 1 in the bottom left, 2 in the middle, and 3 in the top left. Same rules apply.. CMA Rahul Mench 9422416335

64. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 44 45 46 47 48 49 40 18 CMA Rahul Mench 9422416335

65. Having now made a significant step forward, and having ignored “Shine” for this exercise, we must “Standardize”. Since we are dealing with numbers 1 to 49 in sequence, it seems logical to re-organize them in a standard way that makes the completion of the work task as easy as possible. This should ensure that everyone is able to complete the task (and therefore produce a team score of 49.) CMA Rahul Mench 9422416335

66. Numbers from 1 to 49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 42 43 44 45 46 47 48 49 40 18 CMA Rahul Mench 9422416335

67. To show respect for Standards it is necessary to make the “management” of the area visual. Returning to our original work area, we have for this assignment two numbers missing. We cannot complete the task without these numbers - so first we have to find them. Start a clock running and Time :60 seconds,. CMA Rahul Mench 9422416335

68. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 43 44 45 46 47 48 49 50 51 52 53 54 54 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 40 CMA Rahul Mench 9422416335

69. Now how much easier is it to find the quality problems? CMA Rahul Mench 9422416335

70. Numbers from 1 to 49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 43 44 45 46 47 48 49 40 CMA Rahul Mench 9422416335

71. THANK YOU FOR LISTENING CMA Rahul Mench 9422416335