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Welcome Participants

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

 Goal of 7S program is to make the work area


the most efficient and productive possible .

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7S PHILOSOPHY

 Productivity comes from the elimination of wastes.


 There is cost associated with waste.

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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.

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7S PHILOSOPHY

 The time spent looking for a piece of information is


costing you and your company.
 It is necessary to attack the root cause of a
problem.
 Acknowledgement that the human being is not
infallible. ( People tend to forget things)

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eiri
eiton
eiso
eiketsu
hitsuke

afety
ave Earth
What does 7S stands for ?
Japanese English Filipino

SEIRI SORT / arrange suriin / ayusin


SEITON Systematize / orderly sinupin
SEISO Sweep / clean simutin
SEIKETSU Standardize / maintain siguruhin ang
kalinisan
SHITSUKE Self - discipline sariling kusa
SAFETY Safeness / security siguruhin ang
kaligtasan
SAVE EARTH Preserve & conserve pangalagaan at
the environment ingatan ang
kapaligiran
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What is 7S?
 7S is a systematized approach to organize work
areas, keep rules and standards, and maintain the
discipline needed to do a good job.
 It utilizes workplace organization and work
simplification techniques to make work easier,
faster, cheaper, safer, and more effective.
 The practice of 7S develops positive attitudes
among workers, cultivates an environment of
efficiency, effectiveness and economy.

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1 SEIRI
SORTING OUT
(PAGBUBUKOD-BUKOD)

MEANS SORTING THINGS INTO


DIFFERENT CATEGORIES:

 Most frequently used items - closer to your work area.


 Less frequently used items - keep in a distant storage
area.
 not being used - dispose those items.

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…Means to sort through everything in each work area.

 Keep only what is necessary.


 Materials, tools, equipment, supplies, documents, that are not
frequently used should be moved to a separate, common storage area.
 Items that are not used should be discarded.
 Don’t keep things around just because they might be used, someday.
 Sorting is the first step in making a work area tidy.
 It makes it easier to find the things you need and frees up additional
space.
 As a result of the sorting process you will eliminate (or repair) broken
equipment and tools. Obsolete fixtures, molds, jigs scrap materials,
waste and other unused items and materials are disposed of.
How Do We Practice SORTING
Step 1
 Look around you. Are there things belonging to you which are
not of any use anymore?
Examples:
 Outdated diaries w/c do not contain useful information.
 pens which have run out of ink,
 tools which are broken and useless.
THROW THEM AWAY IMMEDIATELY!
Step 2
 Are there things which belong to other people or to the
company which seemed unnecessary?
 We should not throw these away immediately since
somebody else might need them. What we can do is to paste a
disposal notice on the object.
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 The Disposal Notice shall contain information such as:
1. Description of the item
2. Why the item should be thrown away
3. Date when the notice is posted
4. Deadline for replying to the notice.
 The notice must allow time from the owner of the item to
reply as to whether the item should be thrown away.

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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

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2 SEITON
SYSTEMATIC ARRANGEMENT
(PAGSASA-AYOS)

 Systematic arrangement of things for the most


efficient and effective retrieval.
(i.e.. Office supplies, jigs and tools, documents,
spare parts, books, etc.)

 This requires a thorough analysis of current usage.

 Think of your own work area. What arrangement is best


suited for your information retrieval system?

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…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

SEITON means “to arrange necessary items


in a proper order so that they can be easily
picked up for use”.

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.

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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.

Things which are so often used could be


placed slightly further away from your workstation. But
these must also be in proper place so that you can
locate them as and when you need them.

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How Do We Practice SEITON

Step 3

It is likely that we may forget where we have


placed a certain object after some time, especially if
that object is not often used. Prevent this from
happening, we can keep a list of things with their
locations recorded. We could also label of each
drawer/cupboard clearly to show which is kept inside.
If possible decide on how many are to be stored.

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3 SEISO
SWEEP / CLEAN
(PAGLILINIS)

 Cleaning here not only means cleaning but


also includes the analysis of the cause of dirt
build up.
 Regular cleaning can eliminate several steps.
 Ultimate goal of SEISO is to eliminate (or at
least minimize) the need to clean the work area
through the development of innovative ideas.

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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”.

 Do not wait until things get dirty before cleaning


them.
 Clean them regularly so that they do not even have
the chance to get dirty.

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How Do We Practice
SEISO

 Put aside 3 minutes everyday to clean the


workplace.
 be collectively responsible for the cleaning of the
area around the work station.
 never throw anything around or dirty any place.

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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

 Start today. Clean the machines and tools we use.


By cleaning them regularly they will have longer
lives.

 If we and our colleagues share common machine


and tools, we could either take turns to clean the
equipment or do the cleaning together.

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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

I love you, Master, because you care for me.


Please wash my body and joints regularly before I became
dirty and feel itchy.
I will whisper to you when I feel uncomfortable.
So, listen to me carefully and fix me before I become
seriously ill.
I like to work hard for you, Master. I also like to live a long
life.
Master, please understand me a bit more, so that I can
enjoy working with you.
Thank you for your kind consideration.

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4 SEIKETSU
STANDARDIZING
(PAPANATILIHIN)

 Originally meant maintaining a clean


environment all the time.

 Standardize the procedure.

 Without standardization, the situation will


deteriorate right back to old habits

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 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.

“Every well thought-out process is simple.” --Henry Ford


How Do We Practice SEIKETSU
SEIKETSU means “ to maintain a high standard of
housekeeping and workplace organization at all times.

 throw away all unnecessary items and arrange


necessary items in good order.
 Clean the workplace to make sure it’s dust-free.
Do not stop here.
 The next step is to maintain all the good work
done. Here’s how to do it.

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How Do We Practice SEIKETSU

 consciously try to maintain the clean environment,


otherwise, the workplace is dirty again.

 create a maintenance system for housekeeping.

 make a schedule for cleaning and organizing your


workplace.

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SHITSUKE
5 SELF DISCIPLINE
(PAGDISIPLINA SA SARILI)

 continue to train and educate every


member of the organization.
 upgrade the skills and techniques of all the
members so that improvement and higher
productivity can be constantly attained.
 Top and middle management need to take
extra care in discipline
 set a good example to expect the
subordinate to follow standards

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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

 SHITSUKE means…“to train people to follow good


housekeeping discipline independently.”
 SHITSUKE is mainly the responsibility of the management of
a company.
Try to develop a culture within the company, whereby good
housekeeping becomes everybody’s habit.
 SHITSUKE is much easier to attain if all of us play our parts
well.

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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:

 if they notice that your work area,


and machines are dirty, others
create a POOR impression of you
and not of the sweepers.

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Here’s how we can help:

 Treat your workplace as


your second home.

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Here’s how we can help:

 To play a proper role in SHITSUKE, you must also


be aware of own attitudes and habits.
 You may do a lot to clean up and tidy things at
your workplace, but do you unconsciously dirty
them again because of little bad habits?

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6 SAFETY
SAFENESS / SECURITY
(SIGURUHIN ANG KALIGTASAN)

 Clear safety instructions tends to make


safer place to work in.
 By practicing 5S , you actually help to
ensure your own safety and that of your
colleagues.

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7 SAVE EARTH
PRESERVE AND CONSERVE THE
ENVIRONMENT
(PANGALAGAAN AT INGATAN ANG
KAPALIGIRAN)

 Protect and preserve the environment is now a


global concern.
 Manage solid wastes such that they can be
recycled, re-use, and/or reduced.

 Oath to manage hazardous wastes (ODS)

 Help conserve water and energy.


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MEI Global Environmental Policy

“ Fully aware that mankind has a special responsibility


to respect and preserve the delicate balance of
nature, We at Matsushita acknowledge our
obligation to maintain and nurture the ecology of
this planet. Accordingly, we pledge ourselves to a
prudent and sustainable use of the earth’s resources
and protection of the natural environment while we
strive to fulfill our corporate mission of contributing
to enhance prosperity for all.”

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Employees Benefits from Practicing 7S

 improves creativity of people


 improves communication
 improves human relations
 improves teamwork
 enhances comradeship
 gives vitality to people

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Company’s Benefits from Practicing 7S

 improves quality

 improves productivity
 reduces cost
 makes delivery on time
 improves safety
 improves morale

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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

6. Pallet trucks and forklifts must be w/ lights,side,rear mirrors/


properly maintained and painted. back horn/parking area
Category : Jigs and Tools
GUIDELINES STANDARDS
1. Jigs and tools shall be placed
properly during production w/ holder / Hoister
operation.
2. Jigs and tools shall be kept
w/ tool cabinet. toolbox
properly.
3. Moulds and dies must be clean Painted label
and properly identified.
4. Moulds and dies must be treated before storing.
protected.
5. Necessary cleaning tools shall be
provided.

6. Waste disposal bins/containers w/ label


shall be designated.
Category : Floorings, Walls, Ceilings, Surroundings
GUIDELINES STANDARDS
1. Cleanliness of floors must be
maintained. without stains
2. Walls and ceilings be cleaned Painted, not dilapidated,
regularly. No leakages/ no cobwebs
3. Borderlines separating processes
and passageways must be clearly Based on dept’s
indicated. standards documents.
4. Proper ventilations and adequate
lightings shall be provided.
5. Smoking area shall be provided. w/ designated place w/
signs.
6. Exit and entrances shall be w/ signs
clearly identified.
7. Fire extinguishers shall be w/ label
strategically located.
8. Emergency escape route plan Posted in strategic place
shall be provided.
Category : Warehouse Materials
GUIDELINES STANDARDS
1. Should use standard pallet & not
placed directly on the floor. Set by department

2. Should be stock at eye level for w/in 1.5 meters


those materials not in rack.
3. Place directly at designated area. Good/Reject Classification
4. Stocks shall be classified into usage. According to usage
5. Observed proper issuance Follow-in-coming mats.
system. ( labels, tags, etc. ) Procedure.
6. All stocks shall be indicated with Bin Card
information.
7. Removed unnecessary materials. Reject = 1 wk; Phase out = 1 mo.

8. Damaged carton boxes for Based on Dept’s


packaging shall not be used. Use Standards.
standard packaging materials.
Category : Warehouse Area
GUIDELINES STANDARDS
1. Racks shall be maintained in good No structural damage.
condition.
2. Pathways must be separated with Dept. standard
borderlines and must be free from any
obstruction
3. Forklifts, pallet trucks, lifters shall be W/ lights, side/rear
properly maintained and painted.
mirrors/back horn
4. Flooring, window glass, ceiling & fluorescent free from dust & other dirt
housing shall be clean. materials
5. Fire extinguisher and other fire safety with label
equipments shall be strategically located.
6. All electrical controls & other safety devices Not blocked by object w/
shall be visible and easily identified. labels
7. Hazardous/flammable/dangerous materials Based on EPPC designated
shall be stored in a separate warehouse. area.
8. Perimeter set back must be maintained. 0.5 meters minimum
Category : Workers
GUIDELINES STANDARDS
1. No use of jewelry and mobile
phones during production Strictly during operation
operation.
2. Good personal hygiene must be
practiced.
3. Uniform must be properly with ID
wear/used.

4. No eating on production line

5. No personal effects/belongings
shall be present in the production.

6. Appropriate type of shoes shall No open shoes, no


be used in the production line. slippers.
Category : Office
GUIDELINES STANDARDS
1. No unnecessary documents or reference Clear after office hours.
materials on tables/desks or drawers
2. Electrical gadgets/wiring of equipments shall -Fixed wirings
be safe. – w/ wire binder
3. Displays, bulletin,monitoring and white boards - Update
are up-to-date & clean. -Tidy
4. Office furniture & other fixtures - No damaged
shall be safe to use and clean. - Good Conditions
5. Files and cabinets shall be properly identified. - with labels
- with identification marks
6. Disposal of waste materials shall be - No over spillage
properly/strictly followed. - with covers
7. Smoking is done only on the designated area. - with cigarette butt bin
8. Personal effects must be properly contained - with designated area
and maintained.
9. Emergency exits and safety equipments are
- accessible / No obstruction
in placed and always available.
10. There shall be a designated person, Officer - Check list specifying in-charge
of the Day during long vacations.
11. Maintain good housekeeping - Clean and orderly
Category : Toilet / Locker
GUIDELINES STANDARDS
1. Toilet shall be properly maintained. Clean, Dry flooring no foul
odor.
2. Water piping shall be free from leaks and - No leaks
damages.
3. Walls and ceilings shall be regularly clean - Clean / no writing, painted,
no leakage no cobwebs.
4. Proper disposal of toiletries shall be - with waste can
practiced
5. Detergents and hand soaps shall be - with cleaning agents
provided
6. All toilet bowls must be clean and used
- with bidet
only for essential effects.
7. Lockers must be clean and used only for
essential effects. - with designated area

8. Locker Area / Lounging Area must be


clean, well ventilated, well lighted and
free from foul odors
KEY POINTS IN THE
IMPLEMENTATION OF 7S

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.

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KEY POINTS IN THE
IMPLEMENTATION OF 7S

POINT 3

 Only 1 or 2 or 3 S’s are enough for the initial


practice, not all 7S’s.
 First 3S’s (SEIRI, SEISO, SEITON), are ACTION
WORDS.
 4th S - SEIKETSU is a CONDITION.
 5th S - SHITSUKE is accordingly CULTURE.

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KEY POINTS IN THE
IMPLEMENTATION OF 7S

POINT 4

 Set simple , easily achievable and step-by-step


targets.

 THEMES are helpful to concentrate efforts and


achieve greater results.

 Practice 7S together with other movements.

 Integration through selection of common


themes.

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KEY POINTS IN THE
IMPLEMENTATION OF 7S

POINT 5

 Everyone’s participation is important.


 TWO heads are better than ONE.
 FOUR EYES see more than TWO.
 Encourage participation first by EDUCATION then
by DEMONSTRATION, later through ACTUAL
PRACTICE and of course RECOGNITION.
 Set aside a DAY for launching (e.g. Big Clean-Up-
Day).

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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.

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KEY POINTS IN THE
IMPLEMENTATION OF 7S

POINT 7

 Record improvements for comparison.

 Situation appraisal.

 Record starting points/benchmarks.

 Spot Shooting / Fixed Photography


Method
Action vs. Documentation

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KEY POINTS IN THE
IMPLEMENTATION OF 7S

POINT 8
Devise scheme to stimulate awareness and sustain enthusiasm
PROMOTION IMPLEMENTATION
SCHEMES SCHEMES

Banners Big Clean-Up-Day


Slogans 7S Day
Posters 3-Minute Cleaning
Newsletters Study Tour
Badges Spot Shooting
Competition One Point Lesson
EVALUATION
CEO’s Inspection Tour 7S Evaluation sheet
Audit by External Consultants Exchange Visits
Periodic Review

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PCP 7 S ACTIVITY

AUDIT RESULT / EVALUATION


AREA TARGET TARGET LEVEL 5
OCT. '02 JAN. '03 FEB. '03
1. Reduce In-process & Mat'l Inventory.
2. Dispose / Repair defective items.
PRODUCTION 165 80 96 100 3. Maintain cleanliness, arrangement and
orderliness

1. Provide mat'ls directory & location.


2. Proper labelling of mat'ls & racks.
WAREHOUSE 80 38 45 46 3. Min. and max. inventory per item.
4. Correct inventory act'l vs. computer output.
1. Maintain office/locker/toilet cleanliness and
arrangement.
OFFICE/TOILET
/LOCKER 95 51 58 60 2. Clean storage, maint. rooms and other
unmanned areas, and dispose unnecessary
/STORAGE ROOMS
items.

1. Clean and maintain areas outside


BUILDING AND
FACILITIES 50 25 31 30 buildings.
2. Improve electrical wirings.

POINTS 390 194 230 236


TOTAL
LEVEL 5 2 3 3

* Untidy workplace/ * Clean office, C.R. * Improvement LEVEL OF 5 S


surroundings and prod'n area. of 5 S in whse.
* Mixed good and * Segregation and (cleaning,
GENERAL Level 1 0 - 119 points
rejected items. disposal of rejected arrangement of
COMMENTS AND * Poor Level 2 120 - 199 points
materials. materials)
OBSERVATION maintenance of Level 3 200 - 274 points
* Improved on safety * Maintain clean
facilities and safety aspects. office, CR, and Level 4 275 - 354 points
aspects. production line. Level 5 355 - 390 points
DEPARTMENTAL 5S LEVEL EVALUATION
(MANUFACTURING DEPARTMENT)
( BASED ON AUDIT POINTS)
400
TARGET 390
POINTS

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)

TOTAL PCP = LEVEL 3


TOTAL PCP
50

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

BEFORE AFTER 5S BEFORE AFTER 5S

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

BEFORE AFTER 5S BEFORE AFTER 5S

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

LOCATION: PRODN./WINDOW ASSY. LOCATION: REAR SIDE OF THE BUILDING

BEFORE AFTER 5S BEFORE AFTER 5S

SORT SORT
SYSTEMATIZE SYSTEMATIZE

SANITIZE SANITIZE

STANDARDIZE STANDARDIZE
SELF- SELF-
DISCIPLINE DISCIPLINE

OBSERVATION: DATE ACTION: DATE OBSERVATION: DATE ACTION: DATE


OBSERVED: IMPLEMENTED: OBSERVED: IMPLEMENTED:
Rear side of the
Mix material -Segregation - Segregation
Jan. 28, building is being Jan. 28, Feb. 2003
Feb. 2003 - Disposal
stack. 2003 -Disposal used as a 2003
- Arrangement
Arrangement temporary - Cleanliness
-Cleanliness & storage area for & Orderliness
Orderliness parts, materials,
tools and
equipments.
HOW TO MOTIVATE PEOPLE TO
PRACTICE 7S

I. 7S Evaluation Sheet
II. Fixed Point Photography Method
III. Inter-departmental Competition

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WHAT IS SCIENTIFIC ABOUT 7S

 it is scientific because the effect is


measurable.
 It is, therefore important for you to document
the current status of your work and work area
before you start the program.

Implementation
 top management’s understanding,
commitment and positive involvement in the
program is required.

27
FACTORS LEADING TO SUCCESS OF 7S

 Strong sponsorship and leadership of CEO.


 Active promoters/7S committee.
 Good launching activity.
 Regular audits.
 Good documentation.
 Visit by external consultants.
 Competition.

36
FACTORS WHICH HINDER
SUCCESS OF 7S

 Project sponsor is not the decision maker.


 Organizational politics.
 Lack of experience in undertaking cross-functional
activities.
 Lack of top management support.
 Implementation carried out through orders from
the top.
 Implementation done by task forces.
 7S treated as a project.
 Emphasis on immediate results.
37

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