5s trg manual woil pro

WOIL PRO 09WOIL PRO 09

A STRATEGY FORPERFORMANCE EXCELLENCE


What is 5S ?

■ An essential step required for Waste Elimination

■ An integral step in Kaizen■ A required element to achieve Lean-site

Manufacturing.

Systematic Organization

“Seiri”

Orderliness

“Seiton”

Cleanliness

“Seiso”

Cleanup

“Seiketsu”

Cleanup

“Seiketsu”

Standardization/Perseverance

“Shitsuke”


5S Performance Excellence Model

Systematic-Systematic Organization

Scrubbing clean

Self-Discipline-

Control

Customer Expectations

Sorting Visual Placement

Standardizing Control

Improved Quality

Improved Safety

Reduced costs

Consistent Deliveries

Improved Product/ Service Options


Improvement (Kaizen) Principles

Get rid of all old (false) assumptions. Don't look for excuses, look for ways to make it happen . . Don't worry about being perfect - even if you only get it half right “start NOW”! It does not cost money to do KAIZEN or 5S If something is wrong “Fix it Here &NOW”. Good ideas flow when the going gets tough. Ask "WHY" five times - get to the root cause. Look for wisdom from Ten people rather than one. Never stop doing KAIZEN & Sustain 5S


1 ‘S’ – Our respiratory system sorts oxygen and other gases. And exhales other gases which are unwanted for our body

1 ‘ S’ - SEIRI


2 ‘S’ – In our body there is a fixed place for every organ.

2 ‘ S’ - SEITON


3 ‘ S’ - SEISO

3 ‘S’ – We keep our body clean everyday by having bath and cutting nails etc


4 ‘S’ – In every human being the structure of fingers are same I.e Standardised. If it is not so, then we call it is

abnormal.

4 ‘ S’ - SEIKETSU


5 ‘S’ – Every human body has its standard process which they maintain.

5 ‘ S’ - SHITSUKE


1 ‘S’Seiri

Sort for . . .

Not Needed at All

Needed but not Now

Needed but not here

Needed but not so much Quantity

1 ‘ S’

WANTED UNWANTED


Example: Jigs & tools

Anybody

Immediately

Can See

Can take out

Can return

Where – Fix the position

What – Fix the item

How Many – Fix the Qty


Clean Procedure:

Decide what to clean

Decide who is in charge of each cleaning

Decide on cleaning method

Prepare cleaning tools and equipment

Implement cleaning


WHAT TO DO STANDARDISATION . . .

Workstation layout,work area layout

Work in progress

Sequence of work

Material & tools used

Machine & their process parameters

Quality parameters, methods of measurement & reporting methods

5 W’s and 1 H


ENSURE . . .

Procedure & Work Instruction are correct.

Standard are expressed in specific.

Visual Aids are used.

Train at all levels.

Work ethics for effective management.

Transparent & Discipline work culture.


Why 5S

•To eliminate the wastes that result from“uncontrolled” processes.• To gain control on equipment, material & inventory placement and position.• Apply Control Techniques to Eliminate Erosion of Improvements.• Standardize Improvements for Maintenance of Critical Process Parameters.

Look Familiar?


■ Overproduction■ Delays (waiting time)■ Transportation■ Process■ Inventories■ Motions■ Defective products■ Untapped Resources■ Mis-used Resources

9 Wastes

The Nine types of wastes.


■ Overproduction ______________________________■ Delays (waiting time)__________________________■ Transportation _______________________________■ Process_____________________________________■ Inventories__________________________________■ Motions ____________________________________■ Defective products ____________________________■ Untapped Resources __________________________■ Mis-used Resources ___________________________

9 Wastes

Give an example of each type of waste.

The Nine types of wastesThink Break


Stop accidents through good housekeeping

•Tripping over loose objects on floors, stairs and platforms.• Articles dropping from above•Slipping on greasy, wet or dirty surfaces. • Striking against projecting, poorly stacked, or mis- placed material• Tearing the hands or other parts of the body on projecting nails, wire, steel strapping on bales or crates, etc.

Typical examples of poor housekeeping that lead to these accidents are:

• Excessive material, waste or chips in the working area. • Congested aisles. • Tools left on machines. • Waste Containers overflowing. • Lockers and workrooms in disorder. • Acids in open containers.• Broken glass. • Electric leads or air lines across aisles. • Dirty light fittings, windows and skylights.


We must maintain following :

■ Gangways are always maintained clean and clear■ Everything has place and is kept there only■ Waste disposal is ensured time to time and area is kept clean■ Material layout IN & OUT is proper with adequate storage facility.■ Frequency , Quantity, limits, container size , location for each material is as per norms.■ Floor is clean and is without oil, grease , dust or dirt always.■ First Aid box is well maintained and is at its place.■ Fire control equipments are well maintained.■ TPM schedule / 5S schedule is regularly adhered.■ WE WILL CARE FOR OUR ITEM WASTE DISPOSAL■ WE WILL ENSURE NO MATERIAL IS ON THE FLOOR. ( ONLY FOOT ON FLOOR )


ii.Documentation

i.Seperate Location

Procedure - red tag5

maximum and minimum level of storing?

iv) Is storage space properly marked for

iii) Have they been properly identified?

ii) Condition of items in almirahs and tool boxes

i) Do they stock and store at prefixed place?Storage Material4

c) Rejection

b) To be rework

a) To be used

iii) Is their proper place for materials.

ii) Are they having proper identification?

i) How parts/work in progress kept?Parts & Material3

v. No chipping or paint flaking on floors

iv. Floors clean

iii. No defectives scatter about

ii. No trash or parts on floor

i. No oil spilled on floorFloor2

ii. Every Operator knows his "5S" responsibilities.

delineated at line level.

i. "5S" Responsibilities are clearlyArea Management 1

543210

ScoreCheck PointsCheck ItemSl. No.

2S Audit Check Sheet


Before 5S

After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)

Some 5S Examples


Some evidence of standardized work areas

•Clear, shiny aisle ways

•Color coded areas

•Slogans, banners

•No work-in-process ( WIP )

•One-Piece Flow

•Standardized Work Sheets


5S Examples - Sort, Set in Order

See the difference?

1. Sort - All unneeded tools, parts and supplies are removed from the area2. Set in Order - A place for everything and everything is in its place


5S Examples - Shine

3. Shine - The area is cleaned as the work is performed (best) and\or there is a routine to keep the work area clean.


Before shine after shine


The Good, Bad and the UglyFirst the Bad and the Ugly - Life Without 5S


The Good


Nice place…!

There is no second chance to make the first impression!


We must bring to this level.

VW assembling plant

Date post:	12-Jul-2015
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