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Date:-2nd Dec.

2014

Presentation
on
“5S Implementation“
‘A Strategy for Performance Excellence’
Objective of Presentation:-
1. To learn Definition & understanding of 5S.

2. To understand benefits of 5S.

3. Auditing System.

Purpose of 5S Implementation:-

1. To improve the organisation and working standards of the


work environment.

2. To create a work environment that supports safe working


practices, right first time quality and efficient, productive
working
Topics covered :-
 Define 5S .

5S Terminology.

5S Benefits: Cost, Quality, Productivity etc.

The Concept of RED-TAG area.

Explain Each ‘S’ in detail for better understanding of 5S Concept.

Best practices to implement 5S ( Examples).

Color code standards .

5S checklist for audit.


Define 5S :-
“An organizational methodology originating in Japan that, when
implemented, reduces the waste of resources and space while increasing
operational efficiency.”

“ The 5S elements, translated into English, are Sort, Set in Order,


Shine, Standardize and Sustain and are applied in some companies'
efforts to achieve "lean manufacturing.”

5S is also the foundation for Continual Improvement (CI) and Lean


implementation
5S Terminology :-

1. Sorting :- “ Separating the needed from the not-needed.”

2. Simplifying :- “A place for everything and everything in its place,


clean and ready to use.”

3. Systematic Cleaning :- “Cleaning for inspection.”

4. Standardizing :- “ Developing common methods for consistency.”

5. Sustaining :- “ Holding the gains and improving.”


The Benefits of the 5s System :-
Increases in Productivity : -

1. Reduces lead times thereby improving product delivery times


2. Reduces equipment downtime, maintenance and cycle time
3. Improves daily and shift startup times and reduces changeover time
4. Reduces the amount of time wasted
5. Searching for tools and equipment
Increases in Quality : -

1. Improves quality by reducing the amount of errors/defects.


2. Implements standardization thereby achieving output consistency .
3. The pleasantries of the simplified work environment increases employee moral.

Reduction in cost :-

1. Provides cost-savings by reducing inventory, storage fees and


space requirements
2. Improves safety thereby reducing the cost of worker injuries
3. Reduces the amount of scrap thereby reducing production cost
The Concept of Red Tag & its area :-
“ The red tag system is simply a communication tool used to identify items
that a person has flagged for removal from a work area. While the tagging
is most frequently done during kaizen events, it can be done at any time.”

Red Tags:-
1. Red tags come in a wide range of
shapes and sizes, but the most
commercially available red tags will
have a wire or elastic loop on
them to attach to the item.

2. The information you need on the red


tat, at a minimum, includes the
name of the tagger, the reason it was
tagged, and the date it will be
removed.

3. More information may also be


required, especially if the item is to be
moved
to a red tag area. The additional
information helps to catalog or sort
the equipment.
Red Tag Area:-

1. The red tag area is simply a storage location for red tagged items that is
segregated from the production areas.
2. It must be kept neat and orderly so the equipment available in it can be
quickly surveyed by anyone in need.
3. When a red tag area is well maintained, improvement teams will be more
likely to make use of the red tag area, as they will have a better chance of
finding something they need
The Red Tag Technique:-

The Red Tag Technique involves the following steps:-

1. Establish the rules for distinguishing between what is needed and what is not.

2. Identify needed and unneeded items and attach Red Tags to all potentially
unneeded items.
3. Write the specific reason for Red Tagging and sign and date each tag.

4. Remove Red Tag items and temporarily store them in an identified


holding area.
5. Sort through the Red Tag items; dispose of those which are truly superfluous.
Other items can be eliminated at an agreed interval when it is clear that
they have no use.
6. Ensure that all stakeholders agree.

Consider ways to improve the workplace so that unnecessary items do not accumulate.
Explain Each ‘S’ in detail for better understanding of 5S concept:-

Sort:-
Definition :-
"Sorting" means to sort through everything in each work area.
Keep only what is necessary.
Materials, tools, equipment and supplies that are not frequently used
should be moved to a separate, common storage area.
Items that are not used should be discarded or recycled.
Don't keep things around just because they might be used, someday.

Why we do?
1. Removes waste.
2. Safer work area.
3. Gains space.
4. Easier to visualize the process.

How to do?
1. Start in one area, then sort through everything.
2. Discuss removal of items with all persons involved.
3. Use decontamination/ environmental/safety procedures.
4. Items that cannot be removed immediately should be red tagged
Explain Each ‘S’ in detail for better understanding of 5S concept:-

Set in Order:-
Definition :-
The key principle in "5S Set In Order" is: a place for everything and everything in
its place, with everything properly identified , labeled & ready for use.
Arrange workplace for safety and efficiency:-

1. Identify key equipment and supplies


2. Determine location for each item
3. Outline locations and zones
4. Develop shadow boards, label items
5. Document layout, equipment, supplies

Why we do?
1. Visually shows what is required or is out of place.
2. More efficient to find items/ documents (silhouettes/ labels).
3. Saves time, not having to search for items.
4. Shorter travel distances.
How to do?
1. Keep things used together -kept together.
2. Use labels, tape, floor markings, signs, shadow outlines.
3. Sharable items keep at central location (eliminate excess)
Explain Each ‘S’ in detail for better understanding of 5S concept:-

Shine:-
Definition :-
“To keep your area clean on a continuing basis.”

Why we do?
1. A clean workplace is indicative of a quality product and process.
2. Dust and dirt cause product contamination & potential health hazards.
3. A clean workplace helps to identify abnormal conditions.

How to do?
Use a plant layout as a visual to identify individual responsibilities for Cleaning-
eliminates “no man’s land.”
Explain Each ‘S’ in detail for better understanding of 5S concept:-

Standardization:-
Definition :-
“To maintain the workplace at a level which uncovers and makes problems obvious.
To constantly improve our plant by continuous assessment & actions.”

Why we do?
To build 5S’s into our every day process to maintain “neat” and “clean”.

How to do?

1. Build into everyday routines and checklists.


2. Develop schedules and checklists.
Explain Each ‘S’ in detail for better understanding of 5S concept:-

Sustain:-
Definition :-
On-going training and maintaining the established 5S standards.

To maintain our discipline, we need to practice and repeat until it becomes a way of life.

Why we do?

To sustain sorting, storage and shining activities every day.

How to do?
1. Good habits are hard to break.
2. Commitment and discipline toward housekeeping is essential in taking
the first step in being World Class.

5S Focusing Tools:-
1. “Red Tag ” Technique
2. Before & After photographs
3. Improve Area by Area, each one totally
4. Clear Responsibilities
5. Daily Cross Department Tours
6. Schedule ALL Critical Customers to Visit
7. Regular Assessment.
Best practices to Implement 5S ( Example):-
Color code Standards for 5S Implementation :-
Checklist for 5S Implementation :-

5S Workplace Organization
Levels of Achievement
Needed items are routinely Needed items can be Problem sources are M ethods for housekeeping, Root causes have been eliminated and
Level 5: reworked/ replaced as retrieved within 30 seconds documented with solutions labeling, inspections, and improvement actions focus on developing
needed to improve work area and require a minimum defined and implemented work place design are preventive methods
Continuously performance number of steps continually improved and
Improve shared externally as
applicable
Needed items are routinely Needed items have been Daily inspection occurs to Agreements for labeling, Sources and frequency of problems are
Level 4: assessed against business minimized in number/ size and assess area readiness, housekeeping, inspections, documented as part of routine work, root
needs to assure functionality are properly arranged for potential problems are and work place design are causes are identified, and corrective
Focus on and fit retrieval and use identified and fixed consistently followed and action plans are developed
Reliability demonstrate area
performance improvement
A list of needed items for the Needed items have dedicated Visual controls for Work area agreements for Work team is routinely checking area to
Level 3: work area has been locations and are properly equipment, files and supplies needed item labeling and maintain 5S agreements and posting
documented labeled with required have been established for the visual controls are posted results
Make it quantities work area and followed by work team
Visual
Needed and not needed Needed items have been Key work area items to be Work area agreements are 5S level has been determined and posted
Level 2: items have been sorted and safely stored and organized checked are indentified and identified and documented on the communication board
not needed have been according to frequency of documented for needed item organization
Focus on removed from work area use and work area controls
Basics
Needed and not needed Items are placed randomly Key work area items to be No work area agreements There is no measurement of 5S
Level 1: items are mixed throughout throughout the work place checked during a sweep are exist performance
the work area not identified
Just
Beginning

Sorting Simplifying Sweeping Standardizing Sustaining


Road-Map for 5S Implementation Project :-

Action to be required for 5S Implementation at any Organization:-

 Identify 5S Champion or Leader to Lead 5S Implementation Project.


 Formed a Cross-Functional Team for 5S Implementation Project .
 Imparted Training to Team member for Effective execution of 5S Implementation Methodology.
 Define the work area 5S boundaries
 Assign work group members to their 5S areas
 Install a 5S communication board
 Determine 5S targets, activities, and schedule
 Review/finalize plans with work group and site leadership.
 Take work area photos before 5S Implementation Project Start.
 Evaluate current 5S Level of Achievement.
 Define Red-Tag Area .
 Identify needed & not needed Equipment or Item & apply Red-Tag on it
 Shift Red Tag Equipment or Item to Red-Tag area.
 Implemented place for Everything & Everything in its place.( If required develop SOP)
 Mark Gang-Way & Work area as floor marking according to color code & labeling on Equipments or
Items.
 Implemented 3ed S-Shine & Develop Checklist .
 Formed 5S Audit Team & Audit Schedule.
 Started monthly 5S Implementation Project meeting & Appraisal for the best Area.
 Formed & Implemented 5S reward & recognition Policy.
Question & Answer Session :-
Prepared By:-
Pranav B.