Prepared By Mr.

Deepak Kumar Sahoo

AWARNESS TRAINING PROGRAM
Prepared and Presented by :-
Mr. Deepak Kumar Sahoo , TPM Consultant
Basic pillar to implement
- TPM RCM WCM Lean Manufacturing -
Prepared By Mr. Deepak Kumar Sahoo
5S - A new way of thinking for change ?
Think of the rocks and boulders as barriers because they slow
down the water flow. 5S is the first step to eliminate these barriers.
Prepared By Mr. Deepak Kumar Sahoo
Observe the slide carefully . . .
Current Stage Transformation Future Stage
Prepared By Mr. Deepak Kumar Sahoo
5S is short for: Sort, Set, Shine, Standardize and
Sustain
5S represents 5 disciplines for maintaining our work
place
5S is one of the activities that will help ensure our
companys survival.
What is 5S and why do we want to do it?
5S is a systematic development process for creating a clean,
safe and efficient workplace, where it is easy to do right.
Prepared By Mr. Deepak Kumar Sahoo
Steps of 5S :-
1. Sort - Clear
2. Set - Orderliness
3. Shine Clean and make it dust free
4. Standardize Define & Refine
5. Sustain Adherence
Prepared By Mr. Deepak Kumar Sahoo
Benefits of 5S :-
5 S LEADS TO CLEAN & WELL ORGANIZED WORKPLACE
5 S LEADS TO BETTER SAFETY
5 S LEADS TO HIGHER EFFICIENCY
5 S LEADS TO BETTER QUALITY
5 S LEADS TO REDUCTION OF MACHINE BREAKDOWNS
SAFETY EFFICIENCY
QUALITY
ELIMINATING
BREAKDOWNS
5S
Prepared By Mr. Deepak Kumar Sahoo
Do not continue to live with temporary
arrangements.
Prepared By Mr. Deepak Kumar Sahoo
5S
STEP BY STEP IMPLEMENTATION
NOTE : Before implementing SORT, please take photographs
of the various locations and make a note of the date.
The photographs BEFORE to be displayed
at that location.
Prepared By Mr. Deepak Kumar Sahoo
UNIT :- Formaldehyde Plant Unit -4 Doc. No :- TPM/5S/B/A2/1004
Location :- Chemical Lab near SW corner Responsible Person :- Mr. R. Kulkarni
BEFORE 5S (20.10.2010) AFTER 5S (DD.MM.YYYY)
?
COMMENTS :- The searching time was
more. Chemical storage was not proper.
COMMENTS :-
5S activities . . .
Prepared By Mr. Deepak Kumar Sahoo
Meaning
Distinguish between necessary and unnecessary items and
remove all items from the workplace that are not needed for
work place.(parts, tools, equipment, etc).
Activity
Establish a criteria for eliminating unwanted items.
Eliminate unwanted items either by disposing or by relocating.
Uses RED Tag.
Success
Area Save and getting spacious work place.
Reduce the Minor accident and better Spare part management.
SORT = Removal of unwanted items
Prepared By Mr. Deepak Kumar Sahoo
Decide what you need and the
frequency of the tools use.
Remove unnecessary clutter tools,
gauges, materials etc.
Remove items which are broken,
unusable or only occasionally used.
Use Red Tag for disposal.
SORT : How we will approach
Prepared By Mr. Deepak Kumar Sahoo
SORT : Putting Red Tags.
Prepared By Mr. Deepak Kumar Sahoo
SORT : Examples
Prepared By Mr. Deepak Kumar Sahoo
Meaning
To determine type of storage and layout that will ensure easy
accessibility for everyone.
Activity
Functional storage.
Shadow box, Marking.
30 Second rule
Creating place for everything and putting everything in its place.
Success
Time saved in searching
Time saved in material handling & Reduce MTTR.
SET = Systematic Arrangement
Prepared By Mr. Deepak Kumar Sahoo
SET means we arrange items so they are easy to use,
and labeling them so they are easy to find and put
away.
It also means operating efficiency.
Compile LITMUS TEST.
What Does SET Mean?
LITMUS TEST
It is also known as 30 SECOND RULE.
One must locate the items within 30
seconds.
Prepared By Mr. Deepak Kumar Sahoo
Observe the tools carefully.
There are 16 tools.
Prepared By Mr. Deepak Kumar Sahoo
Indicate the tools that are missing here ?
There are 14 tools : which 2 tools missing ?
Prepared By Mr. Deepak Kumar Sahoo
Some more tools missing.
Prepared By Mr. Deepak Kumar Sahoo
How we do in SET process ?
Paint brush 1
Paint brush 2
Drill M/C 1
Measuring tape
Spanner 2 Cutting wheel
Hammer
Torch
Saw Plier
Drill M/C 2
Spanner 1
Vice
Screw driver
Plumber spanner
Horticulture tool
Prepared By Mr. Deepak Kumar Sahoo
Easy Traceability :-
Paint brush 1
Paint brush 2
Drill M/C 1
Measuring tape
Spanner 2 Cutting wheel
Hammer
Torch
Saw Plier
Drill M/C 2
Spanner 1
Vice
Screw driver
Plumber spanner
Horticulture tool
Prepared By Mr. Deepak Kumar Sahoo
Examples of SET in Order. - 1 -
Prepared By Mr. Deepak Kumar Sahoo
Examples of SET in Order. - 2 -
Prepared By Mr. Deepak Kumar Sahoo
Meaning
Cleaning trash, filth, dust and other foreign matter.
Identify and eliminate causes of dirt; find out the root cause.
Activity
Devote 5 minutes everyday for cleaning your work area
Keep workplace spotlessly clean
Inspection while cleaning
Finding minor problems with cleaning inspection
Success
Reduction in machine down time
Reduction in no. of accidents
SHINE = Cleaning For Inspection
Prepared By Mr. Deepak Kumar Sahoo
SHINE means we sweep floors, scrub machines,
apply a fresh coat of paint, and then we keep
it that way.
Create a spotless workplace.
When you Sweep and Shine an area, inspect
machinery, equipment, and working conditions.
Devote 5 minutes everyday for cleaning
your work area
Find out the source of contamination.
Conduct root cause analysis to get the
sources and arrest.
How we will approach ?
Prepared By Mr. Deepak Kumar Sahoo
Meaning
Setting up standards / Norms for a neat, clean, workplace and
details of how to maintain the norm (Procedure).
Activity
Innovative visual management.
CLTI (Cleaning, Lubrication, Tightening & Inspection) Checklist .
Color coding
Early detection of problem and early action
Success
Increase in 5S indicator & better fault finding.
Make things easier for operator.
STANDARDIZATION Easy for work
Prepared By Mr. Deepak Kumar Sahoo
Visual Control refers to the System of Exposing Deterioration or
Displaying the Status, just by making it Visible.
Salient features:
No need to Ask, Think or Walk to get the status
Deviation should Attract the Eye at a glance
Should be Unambiguous / Universal
What is Visual Control ?
HER HIS
Prepared By Mr. Deepak Kumar Sahoo
Visual Controls in daily life
Prepared By Mr. Deepak Kumar Sahoo
A visual factory makes it is easy to do
right and difficult to do wrong...
Shadow boards
ON
SPZ 1600
Prepared By Mr. Deepak Kumar Sahoo
Visual control in Office for Files.
FILES NOT IN ORDER
Prepared By Mr. Deepak Kumar Sahoo
Visual control Examples
Prepared By Mr. Deepak Kumar Sahoo
Meaning
Every one sticks to the rule and makes it a habit.
Activity
Participation of everyone in developing good habits.
Regular audits and aiming for higher level.
5S Training, 5S Competition / evaluation, 5S Posters ,
Literature etc.
Success
High employee morale Indicator.
Involvement of all people.
SUSTAIN = Self Discipline
Prepared By Mr. Deepak Kumar Sahoo
UNIT :- Formaldehyde Plant Unit -4 Doc. No :- TPM/5S/B/A2/1004
Location :- Chemical Lab near SW corner Responsible Person :- Mr. R. Kulkarni
BEFORE 5S (20.10.2010) AFTER 5S (28.10.2010)
COMMENTS :- The searching time was
more. Chemical storage was not proper.
COMMENTS :- Chemical searching time
reduced to 25 seconds. All chemicals are
properly marked. 5S Score 85.7%.
5S : Before and After.
Prepared By Mr. Deepak Kumar Sahoo
5S ENHANCE RELIABILITY.
Prepared By Mr. Deepak Kumar Sahoo
Before and After photographs of 5S
Prepared By Mr. Deepak Kumar Sahoo
5S applied every where.
Prepared By Mr. Deepak Kumar Sahoo
What is 5S ?
Steps of 5S ?
What we do during SORT process ?
What is LITMUS test ?
What are the benefits of 5S ?
What is visual control ?
Difference between STANDARDIZATION & SET ?
Why it is called 5S not 6S or 3S ?
Why we take photographs before 5S implementation ?
5S : All steps ?
5S Review