Friday, 19 April 2019

5S System (Sorting, Systematic Arrangement, Shine, Standardization And Sustain)

5S System
To improve efficiency, work organization, quality, safety and housekeeping and protect investment is tough task to do.
President of Metaltek Mfg. Inc., decided that the 5S process could effectively impact the way his company did business. Based on Japanese words that begin with ‘S’, the 5S Philosophy focuses on effective work place organization and standardized work procedures. 5S simplifies your work environment, reduces waste and non-value activity while improving quality efficiency and safety.
5S System Stands For:-
1 ‘S’ SEIRI – Sorting
2 ‘S’ SEITON – Systematic Arrangement
3 ‘S’ SEISO - Shine
4 ‘S’ SEIKETSU - STANDARDISATION
5 ‘S’ SHITSUKE - Sustain

1 'S' Seiri - Sorting

The first S focuses on eliminating unnecessary items from the workplace. An effective visual method to identify these unneeded items is called red tagging. A red tag is placed on all items not required to complete your job. These items are then moved to a central holding area. This process is for evaluation of the red tag items. Occasionally used items are moved to a more organized storage location outside of the work area while unneeded items are discarded. Sorting is an excellent way to free up valuable floor space and eliminate such things as broken tools, obsolete jigs and fixtures, scrap and excess raw material. The Sort process also helps prevent the JIC job mentality (Just In Case.)
Segregating necessary & Unnecessary and
throwing away what is not Required at all.
(Done with the objective of saving And recovering space)

ØSorting means that you remove all items from the workplace that are not needed for current production (or clerical) operations.
ØCorresponds to the just-in-time (JIT) principle of
  “only WHAT is needed, only HOW MUCH needed. only WHEN it is needed”

Generally Problems , arise if  sorting is not properly Implemented:-
 
1.The factory becomes increasingly crowded and hard to work in.
2.Lockers, shelves, and cabinets for storage of unneeded items put walls between employees, getting in the way of communication.
3.Time is wasted in searching for parts and tools.
4.Unneeded inventory and machinery are costly to maintain.
5.Excess stock-on-hand hides other types of problems in production.
6.Unneeded items and equipment make it harder to improve the process flow.




2 'S' SEITON – Systematic

Arrangement

Systematic Arrangement (SA) focuses on efficient and effective storage methods. Strategies for effective SA are painting floors, outlining work areas and locations, shadow boards, and modular shelving and cabinets for needed items such as trash cans, brooms, mop and buckets. Imagine how much time is wasted every day looking for a broom? The broom should have a specific location where all employees can find it. "A place for everything and everything in its place."

Systematic Arrangement means that  you arrange needed items so that they are easy to use and label them so that anyone can find them and put them away.

STEPS for Systematic Arrangement:-
Step 1: - Decide prefixed locations for all “Moving Items”
               - When an item is in use, put a “In Use” tag in the location   to avoid     confusion (missing item).
  - After the use put the item back in its location.
             - Decide the quantity : Minimum & Maximum
Step 2: Identify the location :
               - Write the names & qty as per the “Standard” for markings
               - Using visual controls
                 So that Anyone can find
Things to be taken care for sustainability
Decide other areas for implementation – Horizontal deployment
Check every day for implementation of 2s.This may be  done during start of the shift.
Get every body to follow rules.
Placement based on Frequency of use

3 'S' Seiso– Shine

The next step is to thoroughly clean the work area. Daily follow-up cleaning is necessary in order to sustain this improvement. Workers take pride in a clean and clutter-free work area and the Shine step will help create ownership in the equipment and facility. Workers will also begin to notice changes in equipment and facility location such as air, oil and coolant leaks, repeat contamination and vibration, broken, fatigue, breakage, and misalignment. These changes, if left unattended, could lead to equipment failure and loss of production. Both add up to impact your company’s bottom line.

Understanding how to prevent things from getting dirty and ensuring tip top condition
(Done with the objective of  Inspecting for problems and  Taking faster Corrective actions)


4 'S' SEIKETSU- Standardization

Standardization means creating a consistent way that tasks and procedures are carried out. When we think “standardization,” we should think “anyone".

(Done with the objective of Achieving higher productivity and better quality through higher employee morale)

5 'S' SHITSUKE- Sustain

This is by far the most difficult S to implement and achieve. Human nature is to resist change and more than a few organizations have found themselves with a dirty cluttered shop a few months following their attempt to implement 5S. The tendency is to return to the status quo and the comfort zone of the "old way" of doing things. Sustain focuses on defining a new status quo and standard of work place organization. Once fully implemented, the 5S process can increase moral, create positive impressions on customers, and increase efficiency and organization. Not only will employees feel better about where they work, the effect on continuous improvement can lead to less waste, better quality and faster lead times. Any of which will make your organization more profitable and competitive in the market place.
Training, Evaluation and Follow up actions.
(Done with the objective Of achieving constancy of Purpose)


Potential Benefits of  5 ‘S’
v  Nice to work in a clean, beautiful,organised workplace
v  Time taken to reach things minimised
v  Lesser time wasted in information Handling
v  Problems detected fast
v  Machine / production down-time Reduced
v  Lower cost of production
v  More usable space
v  Better preventive maintenance     (cond.)

The potential benefits of 5S can be summarized:-  

·Sales - Increase sales (market share).
·Savings - Save costs.
·Safety - Provide a safety working environment.
·Standardization - Standardize the operating procedure.
·Satisfaction - Employees and customers satisfaction. 

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