Reported by: Ms. Laarni P.

Lacandazo

5S is a systematized approach to organized work areas, keep rules and standards and maintain the discipline needed to do a good job.

Just-in-Time Manufacturing (JIT) / Toyota Production System

Is a production strategy that strives to improve

a business ROI by reducing in-process inventory and associated carrying costs.

Hiroyuki Hirano

Quality prevent errors Productivity eliminate wastes Health & Safety prevent accidents Equipment reliability eliminate maintenance breakdowns.

The Bad and the Ugly (Life Without 5S)

Is an action to identify and eliminate all unnecessary items from your workplace.

Eliminate obstacles to make work easy. Eliminate the need to take care of unnecessary items. Provide no change of being disturbed with unnecessary items. Prevent accumulation of unnecessary items.

Apply Stratification Management / Sorting and Evaluation Criteria. Use disposal tags / red tags. Designate storage area. Define disposal procedure. Prepare a material list.

Low Use

Things not used in the past year

Things used only once in the past 6-12 months Things used only once in the past 2-6 months Things used more than once a month

Dispose properly

Store at a distance

Sorting Area

Average

Use

Store in a central place

High Use

Things used once a week Things used everyday Things used every hour

Store near work site or carried by person

Filing

Documents

Categorization Ready access storage Transfer previous year documents Categorization

File Folder Storage of current year documents Storage of previous year documents Storage of 2year old documents

STOCK CARD

ITEM: DESCRIPTION:

Ballpen Black, Panda

STOCK NO.: UNIT PRICE: P 4.75

Date Received or Issued

Requisition or Issue Order Number

From Whom Received or To Whom Issued RRN PRIO-JOC SMO-BOC DAO-CVR

Quantity Received

Quantity Issued

Quantity On Hand

Remarks

9/4/2011 9/6/2011 9/9/2011 9/12/2011 9/13/2011

1001

10 2 4 2 10

10 8 4 2 12 re-order point

1012

RRN

Example: Use of stock cards for inventory of office supplies.

Red Tag Process

One-time activity to remove or disposition clutter

1. 2. 3. 4.

Identify clutter, unused equipment, etc Fill out and attach red tag Note in red tag log Red tags must be dis-positioned within 30 days

14

Red Tag Sample

Is an action to put every necessary items in good order where it is clearly labeled and demarcated. Also known as Straightening or Setting in order

See the difference? 1. Sort - All unneeded tools, parts and supplies are removed from the area 2. Set in Order - A place for everything and everything is in its place

Place goods in wider frontage along passages. Store goods for FIFO (first-in, first out) retrieval. Label items and their location systematically. Separate tools from common ones. Put frequently used items nearer. Only feet on the floor.

Before 5S

After 5S - Cleaned, organized and drawers labeled (less time and frustration hunting)

Is also an action to clean your place thoroughly. Also known as shining or systematic cleaning

Do not wait until things get dirty. Clean your workplace including machines and equipments, tools and furniture so that they do not have a chance to get dirty

Remove dusts and cobwebs from walls. Paint walls and ceilings with bright colors. Prepare cleaning schedules and assign a person responsible for equipment and maintenance of area of storage.

Sweep - The area is cleaned as the work is performed (best) and\or there is a routine to keep the work area clean.

Is a condition where a high standard of good housekeeping is maintained so that there is no dust and rust anywhere. Also known as standardizing.

Color coding Fool-proofing (poka-yoke) Responsibility labels Wire management Inspection marks. Prevention of dirt, dusts, noise and vibration I can do it blindfolded One-point lessons Visual control signs

A technique to enable people to make the rules easy to follow. Use to differentiate normal and abnormal situations and act accordingly with the use of visual aids.

Is a condition where all members practice the 4Ss spontaneously and willingly as a way of life, - a culture. Also known as sustaining the discipline

CLAYGO clean as you go. Eat and smoke at designated area. Keep workplace always clean and tidy. Wear clean uniform and shoes. Follow safety rules. Put things back in their proper place after use. Work according to standards. 30-seconds rule. Only feet on the floor.

There is debate over whether including this sixth "S" promotes safety by stating this value explicitly, or if a comprehensive safety program is undermined when it is relegated to a single item in an efficiency-focused business methodology.

A seventh phase, "Security", can also be added. In order to leverage security as an investment rather than an expense, the seventh "S" identifies and addresses risks to key business categories including fixed assets, material, human capital, brand equity, intellectual property, information technology, assets-in-transit and the extended supply chain.

An eighth phase, Satisfaction, can be included. Employee Satisfaction and engagement in continuous improvement activities ensures the improvements will be sustained and improved upon.

5S Implementation
1. Begin reviewing your areas for 5S 2. Discuss 5S with each of your groups (brief group meeting) 3. Red tag sorting process (one time) 4. Brief, simple daily 5S individual activity (just look around) 5. Brief 5S checklist or procedure for each area 6. Monthly 5S audit beginning __________
Area Lead plus at least one person from outside that area Post results (I will look for them!) Review results with your group Take corrective action

5S Principles
SORT (SEIRI)- Take out unnecessary items and dispose. SYSTEMATIZE (SEITON) Arrange necessary items in good order for use.

Poor
1 A lot of unnecessary things at the workplace. 1 Employee often spend time looking for necessary things

Fair

Good

3 Unnecessary 5 Unnecessary items are things not disposed, but not found at any right away. time. 3 Necessary things 5 Necessary are arranged but things are not in systematic always manner that is arranged for easy to retrieve quick use. and use. 3 Workplace and machines are partially cleaned (center and surface only). 5 Workplace and machines are completely cleaned . Area is free of dust.

SWEEP (SEISO) Clean your workplace completely

1 Workplace as well as the machines are dirty and untidy. Many things are scattered around.

5S Principles
SANITIZE (SEIKETSU) Maintain high standard of housekeeping

Poor
1 No attention is given to keep workplace neat and tidy.

Fair
3 Workplace is tidy but not completely clean.

Good
5 Dust and dirt are completely shut out.

SELF-DISCIPLINE 1 No work (SHITSUKE) Do things discipline. simultaneously w/o People do what being told or ordered. they like.

3 People follow rules. But just to start work on time., without enough preparation for the work.

5 Prepares for work. Comes early to check machine condition. Cleans work area before and after of work.

COMMUNICATION

Inform people what you want to achieve

5S campaign, posters, show 5S video, share/benchmark practices. Orientation and training. Reward individually and group certificates or other 5 minutes before going home cleaning work area.

EDUCATION REWARD

Teach People how to apply 5S Recognize people for their effort. Allow time to clean work area.

TIME

STRUCTURE

Identify what needs to Deputize Tag Team, be done, by whom, Sweep Team, 5S and ensure schedule is Committee updated and visible to all.

Thank you