5S training manual

BetterWork bangladesh 5s trainig

1. Session

2. Background of 5S
5S-CANDO-Six Sigma
5S as part of quality management
Importance of 5S
Waste Management
5S tools
Garments floor and 5S
Action Plan
Objectives of the session
2

3. CANDO Attitude
Henry Ford wrote in his book -Today and Tomorrow (1926): “The first job was
to clean up—that is always the first thing to do in order to find out what you
are about…We cannot afford to have dirt around—it is too expensive. …
Everything is painted and kept painted a light color, so the least bit of dirt will
show. We do not paint to cover up dirt—we paint white or light gray in order
that cleanliness may be the order of things and not the exception.”

4. Six Sigma DMAIC

5. 5-S
KAIZEN
Total Quality Management
Leadership and team work
Quality of services and
management
Working
environment
Positive attitude
Leadership and
commitment of
Management
5S tools are like a fertilizer to grow the root !
Color coding
Safety Sign
5S corner
Sign board
Labeling
Numbering

6. 5S

7. Developed by the Japanese
Housekeeping System
Helps Create a Better Working
Environment and a Consistently
High Quality Process
What is 5S ?
7

8. SEIRI –Organisation/Sort out
SEITON –Orderliness/Systemize
SEISO –The Cleaning/Shining
SEIKETSU –STANDARDIZE
SHITSUKE -Sustain/Discipline
5S Principles
8

9. 9

10. Importance of 5S
10

11. Thinking out of the box

12. Work together and do something with big
positiveattitude?

13. Team work improvement through
everyone’s participation

14. Identify
aBnOrMalITiEs

15. Identify wastes and reduce thewastes

16. Improvesafety

17. Improveproductivities

18. 19
5S –Step 1: SORT
Separate necessary
and unnecessary
items and then
eliminate the
unnecessary ones.

19. 20
Identify all materials which can
be used and should not be
eliminated.
Remove all unidentified
items from area.
5S –Step 1: SORT –What to do ???
Separate necessary and unnecessary items, eliminate the unnecessary
ones
Keep only what you need.

20. 21
Before

21. 22
After

22. 23
Tags are a tool to identify and eliminate
problems
Examine items
in the area
Define
improvement action
Identify a
problem
Fill in and
apply a tag
Solve tag

23. 24
Deployment : 5S Tags
Colors:
Red Unnecessary items to be scrapped
Yellow Useful material to be located in its right place
Green Material to be repaired (e.g. electrical boxes,
assemblies to be dismantled, …)

24. 25

25. 26
There are two copies of each 5S tag : the first
copy (a sticker) is put on the relevant object, the second copy
(plain paper) is placed on the “5S” board
No 1
-Trolley with a
wheel missing
-Paul Wilson
5S BOARD -Separate
Pending tags Solved tags
No 1
-15th Feb. 99
-Paul Wilson
-Trolley with a
wheel missing
Deployment : 5S Tags
-15th Feb. 99

26. 27
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

27. 28
the 3
rd
activity
The Activities
SORT Separate
Identify waste through an initial
inspection
1 Place a 5S tag on fixtures, tools and
materials
Eliminate unnecessary items
5S –Step 1: SORT

28. 29
Tagging is an ongoing task
Tag application
Problem
solving
Attached tags
Solv ed tags
5S Tag register
Preliminary analysis

29. 30
Arrange materials
according to well-defined
criteria so as to cut search
time
5S –Step 2: SET IN ORDER

30. 32
the 1
st
activity
SEITON –Simplify management
Classify items by frequency of use
The Activities
2
5S –Step 2: SET IN ORDER

31. 33
List all necessary items in the table
Descriptionof
item
Frequencyof
use
Most suitable
location
Store location Note
Fill 2 these columns

32. 34
Set classification criteria by frequency of use
Example
Frequency of use Guidelines
Low Once a month
Medium At least one a week
Does not have to be close to the line
Arrange within area, in an
accessible location
High At least once a day
At least once a shift
Keep next to workstation

33. 35
Display the location of each item

34. 36
Workplace Checkpoints
Positions of aisles and storage
places clearly marked?

35. 37
Workplace Checkpoints
Tools classified and stored by
frequency of use?

36. 38
Workplace Checkpoints
Pallets stacked correctly?

37. 39
Workplace Checkpoints
Safety equipment easily accessible?

38. 40
Workplace Checkpoints
Floors in good condition?

39. 41
Clean and orderly arrange the
workplace, identify problems
5S –Step 3: SHINE

40. 42
Clean and check if the order set in the previous step
is maintained
1. Carry out thorough
cleaning
2. Check that Step 2 results
are maintained
3. Take photo to register
abnormal
Before
After

41. 43
Record abnormal to define the root cause

42. 44
the 4
th
activity
Define and carry out the countermeasures
Analyze all the repetitive tags in order to
find out the root causes of the deviations
Tag all the deviations from the desired
situationFind out problems
through cleaning
Clean and check if the order set in the
previous step is maintained
The Activities
3
5S –Step 3: SHINE

43. 45
How to keep everything clean??
1. Should we clean the work place to keep it clean???
2. You should eliminate the source of dirt
Dirt from shoes
Dirt from wheels
Dirt from machine

44. 46
Define and eliminate the source of dirt

45. 47
Check and implement measures for
improving difficult to clean area
-Hang it
-Remove covering

46. 48
Summary
3
5S –Step 3: SHINE
Make a list of the required standards
Find out problems
through cleaning
Define and carry out the countermeasures
Analyze all the repetitive tags in order to
find out the root causes of the deviations
Tag all the deviations from the desired
situation
Clean and check if the order set in the
previous step is maintained
The Activities

47. 49
Define and write
down new
standards for
cleaning, order and
stock levels
5S –Step 4: STANDARDIZE

48. 50
the 3
rd
activity
4
Visual management improvement
Define the check list to verify that
standards are respected
Standardize
Define cleaning and order standards
The Activities
5S –Step 4: STANDARDIZE

49. 51
Basic conditions
The first three steps helped us achieve the best
conditions for the area.
In the future we must ensure to maintain these ideal
basic conditions through the formalization of the
standards.

50. 52
VisualControlisamanagementtechniquewhichemphasizessimplevisual
aidsdevelopedspecificallytoimprovecommunicationbetweenmanagers
andoperators.
Visibilitystronglysimplifiesmanagementactivities.
VisualTools-usedbyoperators,teams,experts,managersand
consultants-helpeverybodykeeptheprocessundercontrolandoptimize
organizationtime.
Visual control

51. 53
Examples of visual control
Deviations from standards must
be easy to identify by everyone,
so as to promptly intervene by
means of corrective measures
everything is easy to find and to see!

52. 54
Standardize
4
5S –Step 4 : STANDARDIZE
Visual management improvement
Define the check list to verify that
standards are respected
Define cleaning and order standards
Comment and Reward regulation
The ActivitiesThe 4
th
activity

53. Right time : Every week, every month
Combine: compliment and reward
Significant
Use chance for promotion
Combined with other rewards program of Company
Set up comment and reward regulation

54. 56
Standardize

55. 57
5S –Step 5 : SUSTAIN
Support continuous improvement

56. 58
5
SUSTAIN-Support Continuous
improvement
Plan audits to verify standard observance
The Activities
4
th
activity
Make problem’s continuous analysis and
identify counter measures
Monitor audit scores
Set new improvement target
5S –Step 5 : SUSTAIN

57. 5S Tools
59

58. Types of 5s tools
•Red tag
•Alignment
•Labeling, Tapes
•Numbering, Alphabetical cording
•Safety signs
•Zone
•Color cording
•5S Corner

59. •Use it when can not decide
an items are “necessary” or
“not necessary”
•Record necessary
information on the Red Tag,
stick or hang it on the item
that cannot make decision.
•If the items is not used for 1
month = Unnecessary item
•If the item is used within 1
month = Necessary item
Red Tag

60. •It is useful to
improve
orderliness and
beautification
when you
organize files,
equipment,
materials and
other items.
Alignment

61. •Labels are used when
you identify each item
and organize them
properly.
•It is useful especially
for storing files and
items in
cabinets/shelves.
Labeling

62. •Used to organize files and
other items by numbers/
alphabets
•It helps users to find
necessary items or
information quickly and
easily.
•It is very useful for practicing
“Can See -Can Take Out –
Can Return” principle.
Numbering / Alphabetical cording

63. •Used to warn visitors and
workers to pay attention on
hazardous items.
•Majority of hazardous items,
which are commonly used
in health facility, has
international/national
standardized safety signs.
•It is recommended to use
common safety signs
Safety signs

64. •Zoning is used to identify or recognize proper location/
storage of items.
•It helps people to understand “where it is supposed to be”
Zone

65. •Color coding makes
facility users understand
the meaning of
“something” by different
colors.
•It is often used for waste
segregation,
categorization of
areas/zones for particular
items
Color coding

66. •Use existing notice board or
establish new one
•Can be displayed:
•5-S posters
•Pictorial progress report
•Implementation progress
chart/table
•M&E information
•Training information
•Production Meeting information
•Mission statement on QI
•Waste bin color coding and type
of waste
•Rules of 5S tools
5S corner

67. Group discussion

71. •Before
•After
Cutting department

72. Pattern keeping

73. Before After

74. 77

75. 78

76. 79

77. 80

78. 81
House Keeping-before

79. 5s-
Housekeeping
83

84. Self Assessment
88

85. Summary
5-S is for you.
Clean-up and organize your work area every day so
that each new day is easier and safer than the day
before
Share your input with your leaders so that the tools
you need will be available to you, increasing your
efficiency.
Volunteer to help with the 5S tours and 5S events.
Take a good look around...Imagine zero waste/zero
confusion!

86. www.betterwork.org
Thank You