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to the
Productivity Thru…
Seminar
Seminar Objectives
1. To inculcate 7S consciousness and practice thus
resulting to a more productive and efficient workforce.
2. To attain a high level of 7S workplace and utilize 7S to
improve the company’s operation.
“ PRODUCTIVITY is above all an
attitude of mind. It seeks to continually
improve what already exists.
It is based on a belief that that one
can do things… BETTER TODAY THAN
YESTERDAY, AND BETTER
TOMMOROW THAN TODAY.”
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7S PHILOSOPHY
3
7S PHILOSOPHY
4
7S PHILOSOPHY
Participation of everyone.
7S is neither for the workers nor for a special
area of the company, it is the contribution to
effective productive work for everyone,
everywhere.
5
7S PHILOSOPHY
6
eiri
eiton
eiso
eiketsu
hitsuke
afety
ave Earth
What does 7S stands for ?
Japanese English Filipino
7
1 SEIRI
SORTING OUT
(PAGBUBUKOD-BUKOD)
9
…Means to sort through everything in each work area.
11
DISPOSAL NOTICE
Inspectors Name : 7S facilitator, Chief Executive Officer, etc.
Description Of item : Inspector to describe item accurately
Date Posted : This is necessary to determine the period
for consideration
Please Reply By: Deadline for reply
OWNERS REPLY
Description: The owner should confirm or correct the
description given by the inspector
Status: eg. Defect item, awaiting delivery, awaiting parts
Disposal Plan: eg. To throw away, relocate deliver to customer,
send to warehouse, date of disposal should be stated
Owner’s Name: Section Leader, Supervisor, Manager etc.
Date: Date of reply
12
2 SEITON
SYSTEMATIC ARRANGEMENT
(PAGSASA-AYOS)
13
…Means to organize, arrange, and identify everything in a work area for the
most efficient and effective retrieval and return to its proper place.
Commonly used tools should be readily available.
Storage areas, cabinets, and shelves should be properly labeled.
Paint floors to make it easier to spot dirt, waste materials and dropped parts
and tools.
Outline areas on the floor to identify work areas, storage areas, finished
product areas, etc.
Put shadows on tool boards, making it easy to quickly see where each tools
belong.
In an office, provide bookshelves for frequently used manuals, books and
catalogs. Label the shelves and books so that they are easy to identify and
return to their proper place.
The objective of this step is: A place for everything and everything in its place,
with everything properly identified and labeled.
How Do We Practice SEITON
Step 1
Look at the way things are arranged in your work
place. Are the things properly arranged according to a
certain system or are they left all over the place?
In carrying out SEITON, always remember that
everything should be in its place. Therefore, you have
first to decide which things should be put where.
Having drawn up a plan on the location of things, you
will be able to find things more easily.
14
How Do We Practice SEITON
Step 2
In deciding which things to put where, you
have to consider how often the things are used. Those
which are needed very often in your job should be
placed very near your workstation so that you can
reach them easily and do not have to waste time
walking a long distance to get them.
15
How Do We Practice SEITON
Step 3
16
3 SEISO
SWEEP / CLEAN
(PAGLILINIS)
17
Regular Cleaning: Once everything, from each individual work area up to
your entire facility, sorted (cleaned up) and organized, it needs to keep it
that way. This requires regular cleaning, or to go along with the third S,
“Shining” things up.
Regular Cleaning and inspection makes it easy to spot lubricant leaks,
equipment misalignment , breakage, missing tools and low levels of
supplies.
Problems can be identified and fixed when they are small. If these
minor problems are not addressed while small, they could lead to
equipment failure, unplanned outages or long-unproductive-waits while
new supplies are delivered.
When done on a regular, frequent basis, cleaning and inspecting
generally will not take a lot of time, and in the long run will most likely
save time.
How Do We Practice SEISO
SEISO means “to clean the workplace
completely so that there is no dust
anywhere”.
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How Do We Practice
SEISO
19
HOW HOW DO WE PRACTICE
SEISO
SEISO does not merely include cleaning of our own
work area. It also includes regular cleaning of
machines and tools which we use as well
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COMPARISON BETWEEN MAN & MACHINE
MAN MACHINE
Sickness Breakdown
Medical Treatment Repair
Rehabilitation Test Operation
Aging Deterioration
health care Maintenance
WHAT MACHINE X SAYS TO HIS MASTER
21
4 SEIKETSU
STANDARDIZING
(PAPANATILIHIN)
22
The good practices develop in steps 1 through 3 should be standardized.
Develop a work structure that will support the new practices and make them
into habits.
As you learn more, update and modify the standards to make the process
simpler and easier.
One of the hardest steps is avoiding the old habits. It is easy to slip back in
to what you’ve been doing for years.
Use standards to help people work into new habits that are part of your 5s
program.
Any easy way to make people aware of, and remind them about the
standards is to use labels, signs, posters and banners.
23
How Do We Practice SEIKETSU
24
SHITSUKE
5 SELF DISCIPLINE
(PAGDISIPLINA SA SARILI)
25
The final step
training and maintaining the standards.
follow-up
continue to educate people about maintaining standards.
make adjustments to accommodate those changes.
think of this step to sustaining the 5s program.
How Do We Practice
SHITSUKE
26
Here’s how we can help:
Always remember the VALUE of your own
housekeeping efforts.
People get a GOOD impression of YOU if they see
that your work area, machines and tools are clean
and neatly arranged.
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Here’s how we can help:
28
Here’s how we can help:
29
Here’s how we can help:
30
6 SAFETY
SAFENESS / SECURITY
(SIGURUHIN ANG KALIGTASAN)
31
7 SAVE EARTH
PRESERVE AND CONSERVE THE
ENVIRONMENT
(PANGALAGAAN AT INGATAN ANG
KAPALIGIRAN)
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Employees Benefits from Practicing 7S
34
Company’s Benefits from Practicing 7S
improves quality
improves productivity
reduces cost
makes delivery on time
improves safety
improves morale
35
Category : Production Materials
GUIDELINES STANDARDS
1. Materials must be properly placed Based on Dept’s
in the designated containers Packaging Standards
2. No materials shall be placed
directly on the floor.
3. Stacking of Materials must be at 1.5 m from floor
a standard height.
4. Materials must be placed w/ dividers/ Diff.
separately with each other. packaging.
5. Standard material inventory level 1 day maximum.
must be maintained.
6. Only Materials of running models
must be on production line.
7. Rejected materials must be Reject/ for repair/
segregated, stored and labeled. Disposal = max. 1 wk.
Category : Machine and Equipment
GUIDELINES STANDARDS
1. All machines must be properly
labeled.
2. Machines must be attached with No leaks, no exposed
history record. ( Maintenance check-up, etc. ) wires, painted
3. Machine wirings and fixtures
must be fixed safely ( covered, etc. )
4. Non-performing/idle fixtures must
be fixed safely ( covered, etc )
5. Piping ( Elec. gas, water, air ) Elec. = Orange – White
Water = Green - White
shall be color coded Oxygen = Black - Yellow
Nitrogen= Gray - White
LPG = Red - Yellow
Com. = Yellow - White
Air = Blue - White
Fire Hose= Red - White
5. No personal effects/belongings
shall be present in the production.
POINT 1
Start small and easy, proceed slowly but steadily.
IF YOU MAKE HASTE, IT IS EASY TO FAIL
For BIG organizations, start with pilot area.
SMALL organizations, can start company -wide.
Trial practice at model area and model machine.
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KEY POINTS IN THE
IMPLEMENTATION OF 7S
POINT 2
Start with the most suitable ‘S’.
For messy workplace, start from 1st S - SEIRI
For troublesome machine, first conduct SEISO
then do SEISO inspection.
Everyone can participate in “SEISO” but they
need to be familiar with machines, proper
cleaning procedures and tools.
SEISO - Inspection requires SPECIALIST.
29
KEY POINTS IN THE
IMPLEMENTATION OF 7S
POINT 3
30
KEY POINTS IN THE
IMPLEMENTATION OF 7S
POINT 4
31
KEY POINTS IN THE
IMPLEMENTATION OF 7S
POINT 5
32
KEY POINTS IN THE
IMPLEMENTATION OF 7S
POINT 6
Management should take leadership of 7S
movement
LEAD by Example
Manage by walking around.
Let people know top management is interested and
watching though may not always be present.
Personally make official announcement.
Make periodic factory tour.
33
KEY POINTS IN THE
IMPLEMENTATION OF 7S
POINT 7
Situation appraisal.
34
KEY POINTS IN THE
IMPLEMENTATION OF 7S
POINT 8
Devise scheme to stimulate awareness and sustain enthusiasm
PROMOTION IMPLEMENTATION
SCHEMES SCHEMES
35
PCP 7 S ACTIVITY
300
200
100
MONTH Oct '02 Jan '03 Feb '03 Oct '02 Jan '03 Feb '03 Oct '02 Jan '03 Feb '03 Oct '02 Jan '03 Feb '03 Oct '02 Jan '03 Feb '03 Oct '02 Jan '03 Feb '03 Oct '02 Jan '03 Feb '03 Oct '02 Jan '03 Feb '03
POINTS 198 216 257 170 222 242 177 236 219 203 229 254 207 258 245 200 225 239 228 261 248 166 195 178
LEVEL 2 3 3 2 3 3 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 2 2 2
RANK 5 7 1 7 6 5 6 3 7 3 4 2 2 2 4 4 5 6 1 1 3 8 8 8
%
Im provem ent 114% 120% 113% 112% 110% 110% 105% 104%
( Oct - Feb)
( BASED ON AUDIT POINTS)
105 TARGET
105
75
50
25
MONTH Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb Jan Feb
POINTS 53 56 54 56 64 64 64 64 63 65 62 64 67 64 67 64 65 62 66 63 71 64 74 65 69 63 64 60 56
LEVEL 2 3 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
RANK 9 6 8 6 7 2 7 2 6 3 7 4 4 2 4 2 6 4 5 3 2 2 1 1 3 3 2 5 6
%
Im provem ent 106% 104% 100% 100% 97% 97% 96% 96% 95% 95% 90% 87% 90%
( Oct - Feb)
25
MONTH Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan '03 Feb '03 Jan Fe
POINTS 53 56 54 56 64 64 64 64 63 65 62 64 67 64 67 64 65 62 66 63 71 64 74 65 69 63
LEVEL 2 3 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
RANK 9 6 8 6 7 2 7 2 6 3 7 4 4 2 4 2 6 4 5 3 2 2 1 1 3 3
%
Im provem ent 106% 104% 100% 100% 97% 97% 96% 96% 95% 95% 90% 87% 90%
( Oct - Feb)
5 S AUDIT AND COUNTERMEASURES
DEPT.: Material Control
LOCATION: WAREHOUSE LOCATION: WAREHOUSE / PRODUCTION
SORT SORT
SYSTEMATIZE SYSTEMATIZE
SANITIZE SANITIZE
STANDARDIZE STANDARDIZE
SELF- SELF-
DISCIPLINE DISCIPLINE
DATE DATE
OBSERVATION: DATE ACTION: OBSERVATION: DATE ACTION:
OBSERVED: IMPLEMENTED: IMPLEMENTED:
- Update Forklift have no OBSERVED:
No proper inventory of permanent Designate
label of Jan. 28, materials by Feb. 10, 2003
parking area. Jan. 28, Parking area Feb. 10, 2003
using Bin
materials in 2003
Card per item ( Frequent 2003 besides
the Warehouse defects on Warehouse
-Update,
area. mounting and vehicle are not office.
material labeling checked and
monitored - Standardize /
- Arrangement of
Materials resulting Designate
downtime / loss parking
- Dispose
unnecessary in operation.)
- Safety
items.
5 S AUDIT AND COUNTERMEASURES
DEPT.: DB/FLT
LOCATION: PRODUCTION LOCATION: WAREHOUSE
SORT SORT
SYSTEMATIZE SYSTEMATIZE
SANITIZE SANITIZE
FLT WHSE SALES
STANDARDIZE STANDARDIZE
SELF- SELF-
DISCIPLINE DISCIPLINE
CHEMICALS WHSE
DATE
OBSERVATION: DATE ACTION: DATE OBSERVATION: DATE ACTION:
OBSERVED: IMPLEMENTED: OBSERVED: IMPLEMENTED:
- Standardize Materials at the
Finished goods the use of Relocation
Oct. 25, storage area Jan. 28, Feb. 2003
items and wooden pallet Nov. 2002 and proper
2002: need proper 2003
materials for materials arrangement. arrangement
containers for and finished of materials in
production are goods the
directly placed containers. warehouse.
on the floor - Arrangement -Cleanliness &
Sanitize Orderliness
Systematize - Standardize
5 S AUDIT AND COUNTERMEASURES
DEPT.: HAD
SORT SORT
SYSTEMATIZE SYSTEMATIZE
SANITIZE SANITIZE
STANDARDIZE STANDARDIZE
SELF- SELF-
DISCIPLINE DISCIPLINE
I. 7S Evaluation Sheet
II. Fixed Point Photography Method
III. Inter-departmental Competition
26
WHAT IS SCIENTIFIC ABOUT 7S
Implementation
top management’s understanding,
commitment and positive involvement in the
program is required.
27
FACTORS LEADING TO SUCCESS OF 7S
36
FACTORS WHICH HINDER
SUCCESS OF 7S