5S TRAINING PPT.pptx

AWARENESS OF 5S IMPLEMENTATION IN INDUSTRIES.

1. 5 “S” Training Module

2. What is 5 “S” 5 “S” Japanese English 1 S Seiri Sort out unnecessary items in the workplace and discard them. 2 S Seiton Arrange necessary items in good order. 3 S Seiso Clean your workplace thoroughly so that there is no dust on floors, machines and equipment. 4 S Seiketsu Maintain high standards of housekeeping at workplace at all times. 5 S Shitsuke Train people to follow good housekeeping disciplines.

3. 5S- Objectives Improve Housekeeping Individual Ownership Beautify by Simple Means Productivity Improvement by saving time, space etc. Provide foundation for continuous improvements 3

4. 5S - Principles Elimination of Waste Team Work Attack Root Cause Sustain the movement Human being is not Infallible 4

5. Seiri = Sorting Frequency of use Storage Method *Things you have not used in the past one year Throw them out *Things you have used once in the last 6-12 months Store at distance OR Keep in store LOW *Things you have used only once in the last 2-6 months Store it in central place in your zone *Things used more than once a month Store it in central place in your zone MEDIUM HIGH *Things used once a week Store near the workplace *Things used daily or hourly Store near the workplace Organization 8

6. Seiri = Sorting Identifying Unnecessary 1. Parts & Work in Process (WIP) Stock of rejected items Items accumulated over period for rework Material awaiting disposal decision Material brought for trial, still lying even after trial Contd.. 9

7. Seiri = Sorting Identifying unnecessary 2. Tools, Toolings Toolings brought for trial, Currently not in use Worn out bushes, liners, toggles etc. Lying unattended Broken tools, bits indisposed 3. Shelves and Lockers Shelves and lockers tends to collect things that nobody ever uses , like surplus, broken items etc. Contd.. 10

8. Seiri = Sorting Identifying unnecessary 4. Walls and Bulletin Boards Old out-dated notices which have lost their relevance Posters or bulletins on wall Remains of torn notices, Cell tape pieces 5. Computer Hard Disk Many unwanted, outdated, temporary files pile up Contd.. 11

9. Seiri = Sorting Dealing with papers How to reduce papers on your table ? 1. Make a single pile of papers 2. Go through them and sort in following categories a) Immediate action b) Low priority c) Pending d) Reading material 12

10. FPP – Fixed Point Photography (Before & After) Fix the views of every zone ( 1 to 3 views) Capture picture (photo) from the same point every time Get suggestions from zonal members & Improve the zones continuously Capture pictures (photos) every month Arrange the photos in chronological order Arrange competition 13

11. XYZ Industries - Surrounding Area Status in Jan.2012 100 Sq. M Area made free from removing unwanted material Status in Feb.2012 Person Responsible :- Mr. ------- (CEO) 05.02.2012 20.01.2012 One Cutting m/c shifted in this area which was previously infront of Office Status in March 2012 Arranged Two Welding m/c in this area Status in May 2012 28.05.2012

12. WPP – Worst Point Pictures (Before & After) Unsafe conditions Excess / insufficient light Open / loose electrical joints Hanging wires, improper parts, accessories No guards for M/cs, Moving parts, Elect. panels Mixed material Obsolete items / tools / dies / gauges / docs Wet floor Out of reach points for cleaning 15

13. Steps for doing SEIRI Sr What to Do? Who Does it? 1 Identify the Coordinator CEO / Plant Head 2 Identify the Zones Plant Head / Coordinator 3 Identify the Zonal Coordinators Plant Head / Coordinator 4 Identify the Red Tags Holding area Coordinator 5 Define the Red Tag Plant Head / Coordinator 6 Establish criteria for Red Tag CEO / Plant Head 7 Establish frequency for doing Red Tag CEO / Plant Head 8 Do the Red Tag All people 9 Identify the Review committee CEO / Plant Head 10 Review the Red Tagged Items & Record Review committee 16

14. PLANT LAY- OUT

15. RAW MATERIAL HANDELING INSTRUCTION RAW MATERIAL STORAGE WITH RACKWISE IDENTIFICATION,COLOR CODE,SPECIFICATION

16. A TYPICAL LAYOUT OF AN OFFICE TABLE DRAWER A PLACE FOR EVERY THING AND EVERY THING IN IT’S PLACE

17. RECORD ROOM BEFORE AFTER

18. FILE CABINETS (inside view)

19. Matching colour for easy identification

20. FILE CABINET

21. PLACE FOR EVERYTHING & EVERYTHING IN IT’S PLACE

22. LAYOUT BOARD BAY IDENTIFICATION

23. Clear Identification

24. STORAGE IN ENGG.STORES

25. CENTRALIZED OIL STORAGE SYSTEM

26. Practice : 5 S Identify 5 S Coordinator, Zones, Zonal Coordinators & Review Committee. Display area of zones, photographs of Zonal coordinator and his team members at appropriate place in the zone itself. Identify Red Tag holding area, define Red Tag, establish criteria for Red tag & frequency. Do the Red Tag as planned, review & record. 40

27. 5 S Zonal Co - ordinator

28. 5M 4.5M 4M 1.3M Toilet 2.4M OFFICE PRESS 12M 9 M 12M 9 M 9 M 8.5M 6 M 5M 3 M 2.5M QA SPOT WELDING & RECEIVING 6M 9 M 9 M PACKING W/C W/C W/C 21.5M 8 M 17.5M Main Gate PLANT LAYOUT with measurements JAYESS INDUSTRIES CO2 WELDING

29. Red tag Campaign Red Tagging Campaign Zone No. Zone Name Red Tag Found Total Pending Tags Red Tag Found Total Pending Tags Red Tag Found Total Pending Tags Red Tag Found Total Pending Tags 01 Office 16 00 04 00 05 02 4 02 Press 13 02 06 01 06 04 4 03 Co2 Welding 14 03 05 00 05 04 3 04 Spot Welding 12 01 03 00 04 03 4 05 Packing & Disp. 14 04 03 02 03 03 3 06 Surrounding Area 09 00 03 01 03 02 02 Total 78 10 24 04 26 18 20 No. of Red Tags (Zone Wise) 1 St Red Tag on 12 Nov.2011 2 nd Red Tag on 24 Jan 2012 3 rd Red Tag on 14 Feb.2012 4 th Red Tag on 16 Mar. 2012 1 st Red Tag 3 rd Red Tag 2 nd Red Tag 4 th Red Tag

30. 5 th Red tag Campaign taken on 28 May 2012 Red Tagging Campaign Zone No. Zone Name Red Tag Found Red Tag Cleared Red Tag pending (16 Mar 2012 ) Total Pending Tags ( Cumulative ) 01 Office 3 3 00 0+2 =2 02 Press 3 3 00 0+7=7 03 Co2 Welding 3 2 01 1+7=8 04 Spot Welding 2 2 00 0+4=4 05 Packing & Disp. 5 3 02 2+9=11 06 Surrounding Area 2 1 01 1+3=4 Total 18 00 36 No. of Red Tags (Zone Wise)

31. LEAN SLOGAN “LEAN की सोच, हमारी सोच रहती है हर पल, BELMAKS में कर लेते, मिलकर समस्या का हल!”

32. 1S, 2S & 3M Training “LEAN की सोच, हमारी सोच रहती है हर पल, BELMAKS में कर लेते, मिलकर समस्या का हल!”

33. 1S, 2S & 3M Internal Training “LEAN की सोच, हमारी सोच रहती है हर पल, BELMAKS में कर लेते, मिलकर समस्या का हल!”

34. Zone Leaders Training Conducted by Mr. Naresh Chauhan Agenda: Motivation for 2S & 3M activity “LEAN की सोच, हमारी सोच रहती है हर पल, BELMAKS में कर लेते, मिलकर समस्या का हल!”

35. Training Conducted by Mr. Tarun Gera Agenda: FIFO & STD. PACKING “LEAN की सोच, हमारी सोच रहती है हर पल, BELMAKS में कर लेते, मिलकर समस्या का हल!”

36. Training Conducted by Mr. G.S. Joshi Agenda: KAIZEN Training to M/c Operaters & Q.C Inspectors “LEAN की सोच, हमारी सोच रहती है हर पल, BELMAKS में कर लेते, मिलकर समस्या का हल!”

37. ZONE 1 PACKING & DESPATCH ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 7 ROLLING, TAPPING & W.I.P. AREA TOOL ROOM & TOOL DIE AREA FRONT VIEW OFFICE & SURROUNDING AREA FORGING & SECONDARY SECTION List of Zones & Zonal Co- Ordinators “LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल !” WIRE STORAGE & Q.C LAB AREA SCRAP YARD ZONE 6

38. PLANT HEAD Mr.Tapan Dey 5S COORDINATOR Mr.Naresh Chauhan LEAN COORDINATOR Mr.Bharat Bhushan 5 S Implementation Team ZONE-1 COORDINATOR Mr.Bharat Bhushan ZONE-2 COORDINATOR Mr.Tarun Gera ZONE-3 COORDINATOR Mr.Prempal ZONE-4 COORDINATOR Mr.Vishvnath ZONE-5 COORDINATOR Mr.Vinod Mishra “LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल !” ZONE-6 COORDINATOR Mr.G.S . Joshi ZONE-7 COORDINATOR Mr.Mukesh

39. ZONE – 1 Office and Surrounded Area Mr. Amit Arora Mr Jagdish Mr. Meharbaan Team Member Team Member Team Member “LEAN की सोच, हमारी सोच रहती है हर पल, BELMAKS में कर लेते, मिलकर समस्या का हल!” Mr. Bharat Bhushan Zone Cordinator-1

40. ZONE - 2   Packing & Dispatch Mr.Tarun Gera ( Zonal Coordinator Zone – 2 ) Miss Rajvinder Kaur Mrs. Nidhi Mrs Beena Mrs.Jamnotri Team Member Team Member Team Member Team Member “LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल ! ”

41. ZONE - 3   Rolling, Tapping & W.I.P. Area Mr. Prempal ( Zonal Coordinator Zone – 3) Mr Baldev Mr Tiwari Team Member Team Member “LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल !”

42. ZONE - 4   Forging & Secondary Section Mr.Vishvnath ( Zonal Coordinator Zone – 4) Mr Ekansh Mr Shailender Mr Rameshwar Team Member Team Member Team Membe “LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल ! ”

43. ZONE - 5   Tool and Tool store Area Mr.Vinod Mishra ( Zonal Coordinator Zone – 5) Mr Ranjay Mr. Satveer Team Member Team Member “LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल !”

44. ZONE - 6   Wire Store & Q.C. Lab Area Mr. G.S. Joshi ( Zonal Coordinator Zone – 6) Mr . Keshav Mr. Viney Pandey Team Member Team Member “LEAN की सोच, हमारी सोच रहती है हर पल, BELMAKS में कर लेते, मिलकर समस्या का हल! ”

45. ZONE - 7   Scrap yard Mr.Mukesh ( Zonal Coordinator Zone – 5) Mr. Anuj Pawar Mr. Rameshwar Team Member Team Member “LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल ! ”

46. Red Tagging Campaign “ LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल !”

47. Red Tagging Campaign “ LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल !”

48. Zone wise WPP Before After “ LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल !” Zone No. 1 : Office & Surrounding Area

49. Zone wise WPP Zone No. 1 : Office & Surrounding Area Before After “ LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल !”

50. Zone wise WPP Zone No. 2 : Packing & Dispatch Before After “ LEAN की सोच , हमारी सोच रहती है हर पल , BELMAKS में कर लेते , मिलकर समस्या का हल !”

51. Thank you