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. WELCOME TO THE TRAINING PROGRAM ON 5 S ONLINE 9 TH APRIL 2021.

Lean manufacturing is a methodology that focuses on minimizing waste within manufacturing systems while simultaneously maximizing productivity ..

L E A N T O O L S. 5S ANDON BOTTLENECK ANALYSIS CONTINUOUS FLOW GEMBA (THE REAL PLACE) HEIJUNKA ( LEVEL SCHEDULING) HOSHIN KANRI (POLICY DEPLOYMENT) JIDOKA (AUTONOMATION) JUST IN TIME (JIT) KAIZEN ( CONTINUOUS IMPROVEMENT) KANBAN (PULL SYSTEM) KPIs (KEY PERFORMANCE INDICATOR) MUDA (WASTE).

5 S. A LEAN TOOL TO ACHIEVE WORKPLACE EXCELLENCE.

Image result for 5s images. 9/30/2021. 5. 5S.

. 5S REVEALS ABNORMALITIES AT THE WORKPLACE . IN A NORMAL COMPANY, ABNORMALITIES ARE IGNORED, INVISIBLE, UNSOLVED ,UNTOUCHED. SUREST WAY TO ELIMINATING ABNORMALITIES IS BY IDENTIFYING AND SURFACING THEM..

EXERCISE 1 (SHEET 1). YOU HAVE BEEN GIVEN A SHEET WITH THE NUMBERS 1 TO 90 . THESE ARE SPREAD ALL OVER THE SHEET IN RANDOM ORDER. STRIKE OFF 1 TO 49 IN A SEQUENCE . YOU WILL GET 1 MINUTE. STOP AFTER 1 MINUTE. THE NUMBER WHICH YOU REACHED WHEN THE 1 MINUTE GOT OVER IS YOUR SCORE. MAKE A MENTAL NOTE OF IT.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

HOW MANY REACHED 49? HOW MANY CROSSED 40? HOW MANY CROSSED 30? HOW MANY CROSSED 20? HOW MANY CROSSED 10?.

IMAGINE THIS IS YOUR WORKPLACE AND ALL THE NUMBERS ARE THE ITEMS YOU REQUIRE TO COMPLETE YOUR TASK YOU NEED ONLY ITEM 1 TO 49 YOUR TASK WAS TO STRIKE OFF ONLY FROM 1 TO 49 YOU DID NOT NEED NUMBER 50 TO 90 TO COMPLETE YOUR TASK THE NUMBERS FROM 49 TO 90 ARE MAKING YOUR TASK DIFFICULT AND HAVE NO BUSINESS TO BE THERE..

REMOVE THE NUMBERS FROM 50 TO 90. SOLUTION. EXERCISE 2 ( SHEET 2).

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

HOW MANY REACHED 49 ? HOW MANY CROSSED 40 ? HOW MANY CROSSED 30 ? HOW MANY CROSSED 20 ? HOW MANY CROSSED 10 ?.

SO WHAT MADE THE TASK EASIER ? WE ELIMINATED THE NOT REQUIRED ITEMS FOR OUR TASK. WE REMOVED THEM FROM OUR WORKPLACE WE DID SORTING..

TARGETS OF SEIRI. DETERIORATED ITEMS. UNUSED ITEMS.

SEIRI (SORTING) DON’T PLACE UNNECESSARY THINGS IN THE WORKPLACE.

STEPS OF SEIRI. 1 . SET CLEAR STANDARDS. DEFINE : “ NECESSARY ITEMS” DEFINE: “ UNNECESSARY ITEMS” CHECK : FOR ITEMS LYING UNTOUCHED OR NON-MOVING FOR A LONG PERIOD OF TIME, DEPENDING ON YOUR CONSUMPTION PATTERN..

2. DO SEIRI AS PER SET STANDARDS. SORT OUT WHAT IS NECESSARY, WHAT IS NOT NECESSARY, WHAT IS DOUBTFUL (RED TAG ITEMS)..

3. TAKE CONTROL MEASURES. PREPARE LIST OF NECESSARY ITEMS BRING INTO THE ZONE NECESSARY ITEMS NOT AVAILABLE PREVENT UNNECESSARY ITEMS FROM ENTERING. MAKE NO SPACE FOR UNNECESSARY ITEMS SEND DOUBTFUL ITEMS TO RED TAG AREA OR RETAIN THEM AT SITE WITH RED TAG.

4. IMPORTANT POINTS TO BE REMEMBERED WHILE DOING SEIRI.

Having achieved some improvement, we now need to move onto the next step ”Set In Order”. We have installed some racking, and we have organized the items so that with Number 1 in the bottom left hand corner, the numbers are located from left to right and bottom to top - examples 1 in the bottom left, 2 in the middle, and 3 in the top left. Cancel the numbers in sequence from 1 to 49 You will be given a time of 1 MINUTE Stop after 1 MINUTE . Observe and make a mental note of your score. Is there an improvement?.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

HOW MANY REACHED 49 ? HOW MANY CROSSED 40 ? HOW MANY CROSSED 30 ? HOW MANY CROSSED 20 ? HOW MANY CROSSED 10 ?.

SO WHAT MADE THE TASK EASIER WITH IMPROVED PERFORMANCE ? WE ARRANGED THE NUMBERS (ITEMS ) FROM 1 TO 49 , MENTALLY IN AN ORGANISED WAY. WE “ SET IN ORDER ”.

SEITON Systematic Arrangement. KEEP THINGS IN ORGANISED MANNER A PLACE FOR EVERYTHING & EVERYTHING IN ITS PLACE.

STEPS OF SEITON. CARRY OUT SEIRI THOROUGHLY. DON’T INCLUDE WHAT IS UNNECESSARY IN SEITON DON’T HESITATE TO THROW AWAY UNNECESSARY ITEMS DON’T INCLUDE DOUBTFUL ITEMS UNLESS THEY ARE DECIDED BY HIGHER AUTHORITIES FOR RETENTION ..

2. DECIDE WHERE TO LOCATE EACH NECESSARY ITEM. PLACE WHAT IS MOST FREQUENTLY USED NEAR TO THE POINT OF USE.

3. DECIDE HOW TO ARRANGE SO THAT TIME IS NOT WASTED IN LOOKING FOR SOMETHING.

ON THE PIECE WITH LABEL / TAG AT THE LOCATION WITH STICKER BOARDS 3. IN A REGISTER / COMPUTER.

Image result for SET IN ORDER SEITON EXAMPLES. npo000008.

The Third S SHINE SEI SO. WE MOVE ON TO THE THIRD S.

KEEP THE WORKPLACE CLEAN & TIDY. SEISO SHINE. GOAL : CREATING SERENE ATMOSPHERE.

WRONG APPROACH- SOMEBODY WILL THROW WASTE AND SOMEBODY ELSE WILL CLEAN ..

SEISO. GC000217. INSPECT AND CLEAN THE AISLES, GODOWNS, SCRAP YARDS AND GARDENS. CLEAN UP WORK PLACE (Shop floor & Office Areas), MACHINES, TOOLS AND OFFICE EQPT AFTER USE. IDENTIFY ROOT CAUSES OF NOISE, VIBRATION, HEAT IN EQUIPMENT AND TAKE REMEDIAL ACTION.

2.IDENTIFY & ELIMINATE SOURCE OF DIRT & DUST. 3S.

3. MEND DEFECTS REVEALED IN CLEANING. tpm3. 3S. 9/30/2021.

SOME FACTS OF LIFE: a) UNTIDY=UNSAFE FOR YOU b) DON’T DEPEND ON OTHERS TO CLEAN UP. CLEAN UP YOURSELF.

Having now made a significant step forward, and having ignored “Shine” for this exercise, we must “Standardize ”. Since we are dealing with numbers 1 to 49 in sequence, it seems logical to re-organize them in a standard way that makes the completion of the work task as easy as possible . Strike off the numbers 1 to 49 For this exercise observe the time in seconds rather than the score..

Numbers from 1 to 49. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

WHAT HAPPENED ? WERE YOU ABLE TO STRIKE OUT ALL THE NUMBERS? HOW MANY OF YOU COMPLETED THE TASK IN UNDER 15 SECONDS? HOW MANY OF YOU COMPLETED THE TASK IN UNDER 25 SECONDS? HOW MANY OF YOU DID NOT COMPLETE THE TASK IN 30 SECONDS?.

BY DOING 4 S, WE WENT FROM. 9/30/2021. 41. 5S.

SO WHAT MADE EVERYONE HERE TO COMPLETE THE TASK IN ALLOTTED TIME OR EVEN EARLIER WE ARRANGED THE NUMBERS (ITEMS ) FROM 1 TO 49 , IN AN ORGANISED (STANDARDISED )WAY. WE “ STANDARDISED”.

INTRODUCE, MAINTAIN AND IMPROVE STANDARDS OF SEIRI , SEITON & SEISO..

Act Plan Check Do. 1.CONTINUOUS REPETITION OF FIRST 3Ss 2.STANDARDISE ALL ACTIVITIES 3. CONTINUOUS UPDATION OF STANDARDS.

SEIKETSU. DEVELOP CLEANING CALENDARS DEVELOP CHECKLISTS INTRODUCE VISUAL CONTROLS FOR EXPOSING PROBLEMS. PROPAGATING SAFETY MEASURES. EDUCATING ON RESOURCE CONSERVATION, ETC,..

SHITSUKE ( SELF -DISCIPLINE ). GOAL : TO ENSURE SUSTENANCE OF 5S THROUGH HABIT FORMATION.

SHITSUKE ( SELF -DISCIPLINE ). 1. RULES MUST BE FRAMED IN SUCH A WAY THAT THEY ARE EASILY UNDERSTOOD AND FOLLOWED 2. RULE MUST BE UNDERSTANDABLE AT A GLANCE 3. WHERE FEASIBLE RULE CAN BE THROUGH PICTORIAL REPRESENTATION 4. FOLLOW RULES UNLESS/ UNTIL THEY ARE MODIFIED 5. NO ONE (WHAT EVER MAY BE HIS / HER LEVEL) SHOULD BE PERMITTED TO BREAK RULES.

SHITSUKE. 1. ADHERENCE TO SET STANDARDS EVERY DAY . 2. CARRY OUT 5S AS A MATTER OF HABIT AND ENTHUSE OTHERS TO PRACTICE 5S. 3 . CONDUCT SELF AUDIT..

EXERCISE 5 SHEET 5. SHEET 5 HAS NUMBERS IS YOUR ORGINAL WORKPLACE WITH QUALITY ISSUES. IT HAS 2 QUALITY ISSUES I.E. 2 NOS ARE MISSING . YOU HAVE TO FIND THE TWO MISSING NOS . NOTE THE TIME IT TAKES YOU TO LOCATE THE TWO MISSING NOS..

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.