Waste Management

(Detection of waste, 5S)

For assistance call:
Amandeep Singh Gujral(Industrial Engineer)
amandeepsgujral93@gmail.com
+91-78375-43000


What is Waste?
Any resource or activity which adds no value
to the output is waste.
Anything which leads to error, defect and
injury is considered waste.

3 Major Categories of Waste
Mura-Unevenness
Muri-Overburdening
Muda-7 types of waste.
Types of Waste
There are 7 types of waste:

Transport Inventory Motion Waiting
Over
processing
Over
production
Rework
Detection of Waste
To start with the process of waste reduction
we have to make waste detectable.
Waste cannot be seen, it can only be detected
by carefully looking for errors, defects and
injuries generated by the system.
Detect non-value adding activities, which are
also waste.
5S Process Flow Diagram
5S implementation is first step
to making waste detectable. For
instance, you cannot see what is
wrong when piles of inventory
are hiding it.
5S not only makes waste
detectable but also eradicates
waste at macroscopic level.
It is a continuous and never
ending process.
Sustain is the most important
step of 5S implementation. If
you ignore the sustain step, you
will end up doing all the four
steps again and again.
Implementation of 5S
As said earlier, 5S is a continuous and never
ending process.
For organization, that is planning to adopt the
methodology of 5S should follow a step by
step approach.
Project No: Date:
Approved by:
Define Objective: Define Current Condition
To implement 5S in ___________________ area.
Walk through the plant and list the various types
of waste you see. Take the help of pictures to
descried them. E.g. piles of inventory, tools
scattered across workplace, etc.
Project Plan Team
Phase Start date: End date: Role Name Dept.
Sort Leader
Straignten Member
Shine Member
Standardize Member
Sustain Member

Project Charter
Sort
Sort the stuff into three broad categories. Take
the help of tags.
Dispose the never used category by
Sending to department which uses them.
Selling it to junk yard.
Sort-Tags
Use these tags to sort the stuff.
Item: Item: Item:
How to Dispose: Frequency of use:
Sending to other department /week
Dept.:
/month
Selling to Junk Yard
/year
Final Decision:
Never Used Ocassionally Used Frequently Used
Keep/Discard
Straighten
Principles:
There's a place for everything and everything in its
place.
Frequently used stuff should be promptly available.
Occasionally used items should be kept at relatively
remote locations.
Label all items so they are easily manageable.


5S Map
It is a floor plan depicting the top view of the
work area.
It is used to identify
Where to locate equipment and machines.
Where storages are needed.
Travel path for movement of humans and
material.

Note: Keep in mind the principles of motion economy before construction 5S
Map.
5S Map
5S Map/Work Place Layout Sheet
Date

Area

Scale

Name

































Labels
Inventory Item Code
Inventory Item Name
Economic Order Quantity
Minimum allowable stock
Kanban Card
Tool ID
Tool Name
Tool Specificattions
Tool Location
Tool Info
Equipment No.
Equipment Name
Equipment Specifications
Equipment Maintainance Std.
Equipment Info
Shine
Principles:
Everything in workspace is "like new"
Equipment, work surfaces, and storage areas
are clean
Garbage and recyclables are collected and
disposed regularly
Whole work place is cleaned and maintained
regularly

RSC Sheet
Regular Shine
Check Sheet
RSC Sheet
Name (Equipment/Area): Responsibility:
Date: Y/N Auditor Comments
01-10-2014
02-10-2014
03-10-2014
04-10-2014
05-10-2014
06-10-2014
07-10-2014
08-10-2014
09-10-2014
10-10-2014
11-10-2014
12-10-2014
13-10-2014
14-10-2014
15-10-2014
16-10-2014
17-10-2014
18-10-2014
19-10-2014
20-10-2014
21-10-2014
22-10-2014
23-10-2014
24-10-2014
25-10-2014
26-10-2014
27-10-2014
28-10-2014
29-10-2014
30-10-2014
31-10-2014
Standardize
Principles:
Development of standards for maintaining and
organizing the work place.
Display the 5S standards throughout the
workplace.
Train the staff about the 5S methodology.


5S Poster
Sustain
Ensure that the above 4Ss are implemented
and followed properly.
Everyone is aware of the standardized
maintenance and work procedures and
practices them daily.
Time and resources should be allocated to the
5S activities.
Conduct 5S audit for evaluation.
5S Audit
5S Maturity
Calculate your organization's maturity level using the above matrix. The levels of all the 5Ss
should be in sync with each other.
Thank You
References:
Toyota way
http://leanman.hubpages.com/hub/Seven-Wastes
http://yalindanisman.wordpress.com/2012/06/08/mura-
muri-ve-muda/
http://www.tpfeurope.com/cms/view/44