5S5S- 5 PILLARS OF VISUAL WORK PLACE

5S- 5 PILLARS OF VISUAL WORK 5SPLACE

THE FIRST PILLER: Seiri means -ORGANISATION --THE RED-TAG STRATEGY THE SECOND PILLAR: Seiton means- ORDERLINESS --THE SIGN BOARD STRATEGY THE THIRD PILLAR : Seiso means-CLEANLINESS THE FOURTH PILLAR :Seiketsu means- STANDARISED CLEANUP THE FIFTH PILLAR : Shitsuke means-DISCIPLINE

WHY ARE THE 5S NECESSARY?

Changing business environment
---competition is growing harsher every year. ---demands more sophisticated products at lower cost. OBSTACLES: Old beliefs, Old concepts, Old customs and Old habits ARE DEEP ROOTED AND NOT EASY TO UPROOT OR REPLACE
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Old Belief
House Keeping should be done by Housewives at home, and by Cleaners and Sweepers at work. Why must we implement the 5Ss? We do not understand why 5Ss are necessary?

They contribute to FAT in the companies. Every ounce of this FAT is pure waste 5Ss IMPLEMENTATION REDUCES THE FAT (WASTE) SIGNIFICANTLY AND IMPROVES THE CORPORATE HEALTH.

Waste arising from unneeded desk supplies (too many pens, pencils, erasers, etc.) Waste arising from unneeded allocation of space and equipment. Wasteful motion in searching, side-stepping, etc. Non-value added actions-picking up, putting down, counting, etc Waste arising from Errors and Defects upsetting the deliveries

Work is more efficient in waste-free office

5S
Similar to taking Bath. Why we take Bath everyday? People practice 5S in their personal lives without even noticing it. Daily routine of Bathing, Dental care and so on are personal hygiene type of 5S implementation in daily life.
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CASE STUDIES

Pallet Shortage Received request to order more Pallets A. Identified 300 Red-Tag. B. 300 Pallet shortage was converted into 300 pallet surplus. C. One third of inventory was eliminated
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Inventory that time forgot

Red-Tag strategy revealed some parts inventory in the ware house that had set for 20 years, without anyone noticing it.

Window-less Wall
First darkness was created by closing the window with empty boxes and then extra Fluorescent Lamps were installed to overcome the darkness

The Rowboat Factory

Filth generated during manufacturing in the Die-Cast Factory was neither prevented nor cleaned periodically. Boots were sanctioned to the people to walk around the place more easily .Boot clad workers might let conditions slide until the water get knee-high and may ask for 10 Rowboats.

Using a wide room

The need for two extra floor to accommodate office staff evaporated with the implementation of Red-Tag strategy (Removal of unwanted items).

A Tale of Needless Suffering

Assistants have to put useless overtime efforts for the misplaced report.

When Reference Material Becomes Immaterial

Reports no longer needed continue to be generated and distributed.
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RESISTANCE TO THE 5SS

Whats so great about Organization and Orderliness? Why should I, the President, Be 5S Chairman? Why clean when it just gets dirty again? Implementing O & O will not boost output.
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My Filing System is in a Mess but I know my way 5Ss and Related Improvements are Just for the Factory. Were Too Busy to Spend Time on O and O Who Are They to Tell Me What to do? We Dont Need the 5Ss Were Making Enough Money, So Just Let Us Do Our work.
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These types of resistance occur at every factory and at every office in the early stages of 5S implementation. If we ignore such resistance and force the 5S implementation, the result will be nothing more than superficial improvements. We must get everyone to truly understand how necessary the 5Ss are while incorporating 5S implementation into ongoing improvement activities.
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BENEFITS: A neat and clean factory or office will have higher output (productivity). A neat and clean factory or office will produce fewer defects/ mistakes A neat and clean factory or office will meet deadlines better. IMPLEMENTATION OF THE 5SS BRINGS MANY DIRECT & INDIRECT BENEFITS.
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Benefits From Six Zeros

1. 2. 3. 4. 5. 6. Zero Changeover Time from one Job to another Bring Operations Diversification Zero Defects / Errors Bring Higher Quality Zero Waste Brings Lower Costs Zero Delays Bring Reliable Deliveries Zero Complaints Bring Greater Confidence & Trust Zero Red Ink (Zero unwanted items at work place) Brings Corporate Growth

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5S Introduction Steps

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Step 1: ESTABLISHING THE 5S PROMOTION ORGANIZATION

5S Promotion Organization

Chairman: MD 5S Council 5S Leader: Head Admin.

5S Patrol Team

5S Team

5S Team

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Step 6: EVALUATION AND FOLLOW- UP

5S conditions are like a stretched rubber-band. Once released, it return to its original shape. 5S will collapse or broken down due to lack of evaluation and follow up. 5S evaluation can be conducted by 5S patrols during routine inspection. External evaluations are also important Strongest force in maintaining 5S conditions is discipline (the fifth pillar). It prevents 5S breakdowns.
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