6S Methodology and its used in automobile sector

5 s methodology is widely used in all tyoes of sector

1. 1
Whatis6s?
❑6S is the methodology to improve the quality, higher
performance and safety in the work environment of any
organization.
❑The 6S method can be implemented in all type of industries or
organization like small scale industries, medium scale
industries and large scale Industries etc.
❑The implementation of 6S method results in improvement in
quality, reduction in wastage and cost, increase in efficiency
and improvement in safety
6S
S1 Sort
S2 Set
S3
Shine
S4
Standar
dize
S5
Sustain
S6 safety
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2. S1
Sort
S2
Set
S3
Shine
S4
Standa
rdize
S5
Sustai
n
❑Theword“5S(fiveS)”wasgeneralizedin1980’sinmanufacturingsectorin
Japan,asToyotaProductionSystem(TPS)becamefamousinthesector
and“5Sactivities”weresetasoneofthebasesofTPS
❑Serviceindustrystartedtoused“5S”in1990’s
❑Developed by Hiroyuki Hirano in Japan to improve organizational quality and
performance.
❑ Widely adopted by many organizations after its introduction.
❑Safety was not a primary focus in the original 5S method.
❑ The 6S method was introduced to prioritize safety alongside equality and
performance.
❑6S can be implemented in all types of organizations or companies.
6S is the advanced version of 5S method
Safety 6S

3. ✓Improve safety
Advantage of using 6S Method
✓Reduce possibility of workers injury.
✓Reduces chances of accident at the
workplaces.
✓Reduce manufacturing cost
✓Reduction in materials
handing cost
✓Create a safe work environment.
Improve communication between
employees

4. ▪Neat and Clean workplace is available.
▪Easy to find tool and use it.
▪Easy to access the all equipment's and
files in the organization
▪Always neat and clean tools are present
at the workplace.
▪All things are in well-organized order.
•Increase quality of products
▪Increase productivity of plant.
▪Increase workplace safety
efficiency of organization
▪Increase workers safety at the
workplace
▪Increase work speed at the
workplace
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5. ✓Identify
Abnormalities
Team work improvement through
everyone’s participation
Save process
time.
Increase
workplace safety

6. ✓Identifywastesandreducethewastes
❑The 7 wastes
Overproduction
Inventory
Waiting
Motion
Transportation
Rework
Overprocessing
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7. Ifno5S&6Sactivities….
Lookingfor
unnecessaryitems
Rememberwhat/
howtodo
Hesitatewhattodo
Makingmistake

8. Aren’tyoufrustratedin yourworkplace?
I cannot remember
what/howtonext…
Why I am making
mistakesagainand
again
Oh, this position
makesmetired!
Whereisthat
document?
Icannotfindit!
Ohtimeis notenough
tocompletethiswork!
Whywecannot
communicate
properly?

9. 6S: Sort-Set-Shine-Standardize-Sustain-Safety
6S
S1
Sort
S2 Set
S3
Shine
S4
standar
dize
S5
Sustain
S6
Safety
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10. S1:Sort
•Focuses on eliminating unnecessaryitemsfromthe
workplace
•Categorizeequipment,
•furniture, tool in your workingplaceintothe following
3categories
1.Necessary
2.Unnecessary
3.Maynotnecessary
•Thisstepwillalsohelpwith
the“justin case”attitude
S1 sort
S2 set
S3 shine
S4
Standardize
S5 Sustain
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11. Equipment,
materials
toolsetc.inyour
workplace
Itemsoftenuseareinthiscategory
Needit
Mayneedit
Notneedit
Equipment,material,toolsfiles,furnitureetc.canbe
categorizedbasedonthefrequencyofuse!
Itemsnotusedincurrentwork
processareinthiscategory
Itemsonlyusedoccasionally
areinthiscategory
S1:Sortingactivities

12. Examplesof“Sorting”
•Place“Redtag”forcategorization ofitemsto identifyunnecessary
items
•Moveunnecessary items(broken tools,obsolete jigs and fixtures, scrap
and excess raw material etc.)to centralstoredarea
•Freeupvaluablefloor space(Space utilization)
•Finding abnormality of equipment and tools (Out oforder,missingparts
etc.)
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13. S2:Set
•“Set” is based on
findingefficientand
effectivestorageof
necessaryitems
•Apply “Can see, Can
take out, and Can
return”philosophy
•This willsavetime
andenergytolookfor
something
S1:
Sort
S2:Set
S3:
Shine
S4:
Standardize
S5:
Sustain
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14. S2:Settingactivities
Haveconsensusamong
co-workerson whereand
howtoorganizenecessary
items
Arrangethemproperlybased on
“Cansee,Cantake-out,Can
return”Philosophy
Thinknot only“beatification.
Need to consider workflow and
arrangeitems
•Neededitems
•Itemsoftenuse
(with current
workprocess)
Use 5S tools for proper
Organization of items
suchas
•Labeling
•Colorcoding
•Numbering
•Zoningetc.

15. Exampleof “Setting” activities
•Labeling,numbering,zoningforclearidentificationofstorageareas
tokeepnecessaryitems
•Setnecessaryitemsmatchingwithworkflowtominimize
unnecessarymovementandtransportationtime
PROCESS

16. S3:Shine
•Cleaning up one’s
workplace daily so
thatthereisnodust
on floors, machines
orequipment.
•It will create
ownershipandbuild
prideinthe workers
S1:
Sort
S2:
Set
S3:
Shine
S4:
Standardize
S5:
Sustain
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17. S3:Shiningactivities
•Cleanfloor,windowsandwalls.
•CleanandMaintainofficeautomation
machines, medical equipment and tools,
office furniture
•Developandfollowregularcleaning
andMaintenanceschedule

18. Exampleof “Shining”activities
•Daily sweeping and mopping of floor, bathroom,corridoretc.
•Regularcleaningandmaintenanceof equipment andtools
•Periodical check for changes in equipment and the service area such as:
leaks, vibration,misalignment,breakageetc.
•IPC activities such as hand hygiene, waste segregationarealsopartof
shine

19. S4:Standardize
•Maintainanenvironment
whereS1to S3are
implementedinthe same
manner throughout the
organization
•Give opportunities to
employeestotakeactive
part in the development
ofthese standards.
S1:
Sort
S2:
Set
S3:
Shine
S4:
Standardize
S5:
Sustain
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20. S4:Standardizingactivities
S1
S2
S3
Developmechanismtostandardize
S1-S3implementationforcontinuation
Standardizationwillleadsequalizationofactivities
=“Productionlevelingandsmoothing”
Standardizationis usefulfor;
•Easyimplementationof S1toS3 activities
•Equalizationprocessoutput
•Everyone’sparticipation

21. S5:Sustain
•Maintain S1-S4
throughdiscipline,
commitmentand
empowerment
•It focuses on
defininganew
mindset and a
standard in
workplace
S1:
Sort
S2:
Set
S3:
Shine
S4:
Standardize
S5:
Sustain
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22. S5: Sustainabilityactivities
Preventfallback
Improvement
FurtherImprovement
Measure improvement with proper
periodicalmonitoring
Peopleget boredifnochanges.
Need to develop a mechanism to
makestaffexitedandmotivated
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23. Exampleof “Sustain”activities
•Regularprogressreporting
•Refreshertraining
•Periodical evaluationof5Sactivitieswith proper advicesfor
continuationand further improvements
•Appreciation,recognitionandawarding ongood5Sactivities
•Reminder using 5S corner, new letters, goodpracticesheetetc.
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24. S6 Safety
Make safety the foundation of
the 6S framework to protect
all employees.
Safety Priority:
PPE Availability:
Provide and ensure the correct
use of PPE, including gloves
and goggles
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25. Emergency Preparedness:
Keep a well-stocked first aid kit
accessible and train employees
in basic first aid
Fire Safety:
Regularly inspect fire extinguishers
and ensure they meet safety
standards.
Routine Maintenance:
Conduct regular checks and
maintenance on all safety equipment
to ensure it is functional and ready

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