Quality Improvements

INDIA
1950 1960 1970 1980
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1. 5S Principles
Elimination of waste Every body is involved, Cooperative effort Attack root cause Human being is not infalliable
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2. Objectives
Improve housekeeping Make every individual responsible for housekeeping Beautify by simple means Productivity improvement by saving time, space etc.
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3. 5Ss
Seiri Seiton Seiso
- Sorting
- Systematic arrangement

- Cleaning Inspection while cleaning

Seiketsu - Standardization Shitsuke - Self Discipline

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5S
If we do not do 5S, we cant do any other work efficiently. They are features which are common to all places and are the indicators of how well an organization is functioning.
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SEIRI = Sorting
Meaning
Distinguish between necessary and unnecessary items and eliminate the unnecessary items Establish a criteria for eliminating unwanted items Eliminate unwanted items either by disposing them or by relocating them. Area saved or percentage of space available

Activity Success Indicator

SEIRI = Sorting
Japanese Meaning : The Japanese meaning of Seiri is to straighten and contain. - Get rid of waste and put it in order according to rules OTHER JAPANESE MEANINGS farmland cultivation, Make an orderly system and straighten
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Seiri = Sorting

What is unnecessary

1. Item is not needed 2. Item is needed however quantity in stock is more than what is needed for consumption in near future 3. Contingency Parts

Critically decide the quantity of contingency parts to be retained and criteria for such parts
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Organization
Frequency of use Storage Method

LOW

*Things you have not used Throw them out in the past one year *Things you have used once Store at distance OR in the last 6-12 months Keep in store

*Things you have used only Store it in central place once in the last 2-6 months in your zone
*Things used more than once Store it in central place a month in your zone

HIGH

*Things used once a week

Store near the workplace

*Things used daily or hourly Store near the workplace

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Seiri = Sorting

Identifying unnecessary

1. Parts & Work in Process (WIP) Things fallen back behind the machine or rolled under it Broken items inside the machine Things under the racks/ platform Extra WIP Stock of rejected items Items accumulated over period for rework Material awaiting disposal decision Material brought for some trial, still lying even after trial Small qty of material no longer in use Contd..
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Seiri = Sorting

Identifying unnecessary

2. Tools, Toolings, Measuring devices Old jigs, tools not in use are lying Modified tools, tooling for trial, are lying after trial Worn out items like bushes, liners, toggles etc. lying Broken tools, bits, etc. may be lying Measuring equipment not required for the operation being performed , is lying 3. Contingency Parts Many times storage place for contingency parts become a last refuge for broken parts, surplus items and things nobody is likely to use Contd..
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Seiri = Sorting

Identifying unnecessary

4. Shelves and Lockers Shelves and lockers tends to collect things that nobody ever uses , like surplus, broken items etc. 5. Passages and Corners Dust, material not required seem to gather in corner 6. Besides Pillars and under the stairs These places tends to collect junk, spittoon etc. 7. Walls and Bulletin Boards Old out dated notices which have lost their relevance Posters or bulletins on wall Dust, remains of torn notices, cell tape pieces Contd..
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Seiri = Sorting

Identifying unnecessary

8.Floor, Pits, Partitions Defective parts Protection caps, covers Packing material Hardware items , small items Even tools, tooling Items dropped on the floor are never picked 9.Computer Hard Disk Many unwanted, outdated, temporary files pile up

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Seiri = Sorting

Improvement methods

1. Flow Process Chart (Procedural Analysis) Drawing a process flow chart for the system eg. How to make and use category wise grouping 2. Operational Analysis Preparing the sequence of operations for system eg. How to perform Seiri (sorting) 3. Check List A check sheet is used to decide what sort of main system and sub system are necessary.
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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 e) For information
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Seiri = Sorting

Dealing with papers

How to reduce papers on your table ? 4 D Principle
DO DELEGATE DELAY DUMP

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SEITION = Systematic Arrangement

Meaning Activity
To determine type of storage and layout that will ensure easy accessibility for everyone . - Functional storage - Creating place for everything and putting everything in its place

Success - Time saved in searching Indicator - Time saved in material handling

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SEITION = Systematic Arrangement

Japanese Meaning: Dictionary meaning of Seiton is to be correctly preparedand to prepare correctly. In short these means :
(a) arrange correctly in accordance with the correct method of doing activities and (b) make thorough preparations so that activities can be done even if they occur abruptly
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SEITION = Systematic Arrangement

The main target areas for Seri-Seiton improvement are : Tool-setting and preparation operations, line balancing and process planning, parts supply to assembly line, peak time problems etc.
Improvement Methods Kit Method / Assembly box method / Outside tool setting Cassettisation / Parallel operations / Changes in assignment method
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Seiton = Systematic Arrangement

How to achieve Systematic Arrangement ? Decide where things belong

Decide how things should be put away

Obey the Put away rules

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Seiton = Systematic Arrangement

How to achieve Systematic Arrangement ? Decide where things belong - Standardize Nomenclature

Decide how things should be put away

- Determine an analytical method of storage

- Name & locations to everything. Label both item

and location - Store material functionally - Prevent mistakes with coding by shapes & colour contd..
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Seiton = Systematic Arrangement

How to achieve Systematic Arrangement ? Decide how things should be put away - Follow first in first out rule
- If two identical items are to be located, then store them separately, colour code them.

Obey the rules

- Put the things back to their location after
their use

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Seiton = Systematic Arrangement USE : 1 ) Signboards 2) Colour codes 3) Outline markings

4) Labels

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Seiton = Systematic Arrangement

Functional

Storage

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Seiton = Systematic Arrangement

Usage Store frequently used material Frequency near the workplace and less
frequently at some distance

Weight & Shape of the Material

Heavy material should be stored at lower levels/layers Place directly on the material handling device for ease of handling

Functional Storage
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Seiton = Systematic Arrangement

Category

Same category of material may be

stored in one location. Eg. Allen Screws, Oil Seals
All items required for an operation may be stored in one location. Eg. Allen key, spanner etc hand tools required for setting m/c

Operation Wise

Functional Storage
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Seiton = Systematic Arrangement

Outlining and Placement Marks - Mark boundaries of dept., aisles, Machines

Stands and shelves

- Follow straight line, right angle rule - Nothing shall be kept outside the boundaries

- Keep only required number of stands and shelves

- Standardize height, size - Provide casters where necessary so that it can be moved

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Seiton = Systematic Arrangement

Wires and Ducts - Colour code

- When there are multiple connections - bundle the wires, label them and make sure that they are in straight line /right angle and firmly anchored

Machine-tools & Tools

- Put the tools in the order you need them

- Location of the tool should be such that it can be put away with one hand - Try to eliminate some hand tools by permanently attaching it to the bolt head
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Seiton = Systematic Arrangement

Blades, Dies, Other important consumables - Store them in the protected place

WIP- Work In Process

- Maintain these things regularly by applying rust preventive, oiling etc.

- Designate a place for each component/part

- Decide on how much quantity to be stored - Ensure that there is no damage to good part during transit, they do not get rusty and they are not mislabeled
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Seiton = Systematic Arrangement

Oils - Reduce number of oils used (Standardize)

- Colour code for oil - Safety aspects - fire prevention, pollution, leak, spillage

Instrumentation & Measuring Devices

- Label them, show direction of flow

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SEISO = Cleaning
Meaning
Cleaning trash, filth, dust and other foreign
matter. Cleaning as a form of Inspection

Activity Success Indicator

- Keep workplace spotlessly clean - Inspection while cleaning - Finding minor problems with cleaning inspection - Reduction in machine down time
- Reduction in no. of accidents
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SEISO = Cleaning
Japanese Meaning : Dictionary meaning to clean up and getting rid of dirt and unclean items While cleaning potential defects such as abrasion, damage, loose parts, deformities, leaks temp., vibration, abnormal sound etc. are revealed hence Seiso is Inspection
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Seiso = Cleaning

Here cleaning means more than just keeping things clean. Cleaning should be viewed as a form of Visual Inspection

Preventive measures should be taken to tackle problems of dust, grim, burrs, leakage etc. Root cause of the problem should be identified and it should be eliminated
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Seiso = Cleaning

Various Minor Defects = Trash = Dirt =Knocking = Loose parts = Leaks =Scattering =Skips =Curvature =Abrasion =Rust =Scratches =Eccentricity =Lurching =Abnormal =Vibration Movements =Abnormal =Heat =Abnormal Sounds smells =Faded colour =Hisses
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Seiso = Cleaning

5 Minutes Every day for cleaning

Devote 5 minutes everyday for cleaning your work area Participation of everyone is required

Attack hard to clean places regularly

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Seiso = Cleaning

Cleaning-Inspection points for most equipment

Grime, clogging, dust balls, rust, Cleaning leakage etc.

Oils

No oil, Low oil, leakage, filter clogging, dirty oil, dirty or bent oil lines, clogged drainage, oil spillage, worn& torn ports etc.
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Seiso = Cleaning

Cleaning-Inspection points for most equipment

Tightening Heat
Loose bolts, welding detachment, loose parts, vibration or bumping noise, friction

Oil tanks, motors, heater, axles, control panels, washing/ cleaning water, bearing, wiring etc.

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Seiso = Cleaning

Cleaning-Inspection points for most equipment

Breakage, Cracks
Breakage, cracks, dent on sliding parts, handle has come off, broken switches, wire joints come off, wires are broken or crack, crack dial of various pre. gauges, meters etc.

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Seiso = Cleaning

Function wise Cleaning check list of equipment

Pneumatics
Compressed Air lines, air valves, connections, meters, filters, reservoirs etc. Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc.

Hydraulics

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Seiso = Cleaning

Function wise Cleaning check list of equipment

Motor fan, fan belt, couplings, Mech & Joints, pulleys, chains, pump Power Train

bearings etc.

Electrical

Control panel, lamps, light, switch, sensors, wiring, ducts, fuses etc.

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Seiso = Cleaning

Function wise Cleaning check list of equipment

Toolings Equipment Specific
Tools, fixtures, gauges, dies, measuring instruments, etc.

Furnaces, rollers, chutes, CNC machines, etc.

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SEIKETSU = Standardization
Meaning
Setting up standards / Norms for a neat, clean, workplace and details of how to maintain the norm (Procedure) - Innovative visual management - Colour coding - Early detection of problem and early action Increase in 5S indicator

Activity Success Indicator

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SEIKETSU = Standardization
Japanese Meaning : Dictionary meaning unsoiled things, purity and cleanliness Clean manners , Clean cloths, clean politician It is the proof that 3 Ss are being faithfully carried out.
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SEIKETSU = Standardization
Tools used for analysis : MTTR MTBF OEE

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Seiketsu = Standardization Regularizing 5S activities so that abnormalities are revealed Make it easy for everyone to identify the state of normal or abnormal condition For maintaining previous 3S, deploy visual management

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Seiketsu = Standardization It has been estimated by scientific study that 60% of all human activities starts with sight

5S is easy to do once.It is consistency that is difficult. That is why Visual Management is so important, so that everybody will know that there is some problem. Visual Management
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Seiketsu = Standardization What visual control communicates ? It grabs one or more of our senses in order to Alert us to an abnormality Help us recover quickly Promote adherence and prevention Enable successful self management
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Seiketsu = Standardization Some methods for visual communication Colour coding Use of Labels Danger alerts Indication where things should be put Directional arrows/ marks Transparent covers Performance indicators
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Seiketsu = Standardization Some methods for visual communication Labels Precision management labels Inspection labels Temperature labels Responsibility labels

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Seiketsu = Standardization Points to remember in making visual c control tools 1. Make them easy to see from distance 2. Put the display on the things 3. Everyone can tell what is right and what is wrong 4. Anybody can follow them and make necessary corrections easily 5. Work place should look brighter & orderly
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Seiketsu = Standardization Some everyday visual management examples Traffic signal Zebra crossing In car - Petrol indicator - Speed indicator Direction arrows Electric danger sign etc.

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Seiketsu = Standardization Some visual communication signs

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SHITSUKE = Self Discipline

Meaning
Every one sticks to the rule and makes it a habit

Activity Success Indicator

- Participation of everyone in developing good habits - Regular audits and aiming for higher level High employee morale
Involvement of all people
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SHITSUKE = Self Discipline

Japanese Meaning : Dictionary meaning is learning of the manners having manners, dressing neatly OR training children for good customs

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SHITSUKE = Self Discipline

Activities : 5S Committee 5S Training 5S Competition / evaluation 5S Month Posters , Literature etc.

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Shitsuke = Self Discipline

We need everyone to maintain 5S guidelines.

To maintain DISCIPLINE, we need to practice and repeat until it becomes a way of life.
Discipline is the Core of 5S
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Shitsuke = Self Discipline

Discipline means making a steady habit of properly maintaining correct procedure.

Time and effort involved in establishing proper arrangement and orderliness will be in vain if we do not have discipline to maintain it.
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Shitsuke = Self Discipline

Pledge

It shall be my constant effort to maintain my workplace in good order by Assigning a place for everything & keeping everything in its place Sorting out unwanted material periodically & discarding them Keeping my work area neat & clean everyday
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Organization
Departments into areas Coordinators at department level Coordinator at each area level Training for all Audit each area and make action check list Implement actions Audit and evaluation on continuous basis

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Implementation Target
TOTAL FACTORY 400 people/month to be trained Every 3 month 25% area will be covered
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