1、S.B.Shinde - Sourcing Quality Assurance,Seiri,Seiton,Seiso,Seiketsu,Shitsuke,Asao svacCta ijaqao ijaqao vasao laxmaI itqao itqao ,5S,S.B.Shinde - Sourcing Quality Assurance,1980,1950,1970,1960,U.S.A,JAPAN,INDIA,Quality Improvements,S.B.Shinde - Sourcing Quality Assurance,1. 5S Principles,Elimination
2、 of wasteEvery body is involved, Co-operative effortAttack root causeHuman being is not infalliable,S.B.Shinde - Sourcing Quality Assurance,2. Objectives,Improve housekeepingMake every individual responsible for housekeepingBeautify by simple meansProductivity improvement by saving time, space etc.,
3、S.B.Shinde - Sourcing Quality Assurance,3. 5Ss,Seiri - Sorting Seiton - Systematic arrangement Seiso - Cleaning Inspection while cleaning Seiketsu - Standardization Shitsuke - Self Discipline,S.B.Shinde - Sourcing Quality Assurance,5S,If we do not do 5S, we cant do anyother work efficiently. They ar
4、e features which are common to all places and are the indicators of how well an organization is functioning.,S.B.Shinde - Sourcing Quality Assurance,SEIRI = Sorting,Meaning Distinguish between necessary and unnecessary items and eliminate the unnecessary items,Activity Establish a criteria for elimi
5、nating unwanted itemsEliminate unwanted items either by disposing them or by relocating them.,Success Area saved or percentage of space available Indicator,S.B.Shinde - Sourcing Quality Assurance,1. Item is not needed2. Item is needed however quantity in stock is morethan what is needed for consumpt
6、ion in nearfuture3. Contingency PartsCritically decide the quantity of contingency parts to be retained and criteria for such parts,Seiri = Sorting,What is unnecessary,S.B.Shinde - Sourcing Quality Assurance,Frequency of use,Storage Method,*Things you have not usedin the past one year,Throw them out
7、,*Things you have used oncein the last 6-12 months,Store at distance ORKeep in store,LOW,*Things you have used onlyonce in the last 2-6 months,Store it in central placein your zone,*Things used more than oncea month,Store it in central placein your zone,AVERAGE,HIGH,*Things used once a week,Store ne
8、ar the workplace,*Things used daily or hourly,Store near the workplace,Organization,S.B.Shinde - Sourcing Quality Assurance,Seiri = Sorting,Identifying unnecessary,1. Parts & Work in Process (WIP)Things fallen back behind the machine or rolled under itBroken items inside the machineThings under the
9、racks/ platformExtra WIPStock of rejected itemsItems accumulated over period for reworkMaterial awaiting disposal decisionMaterial brought for some trial, still lying even after trialSmall qty of material no longer in use,Contd,S.B.Shinde - Sourcing Quality Assurance,Seiri = Sorting,Identifying unne
10、cessary,2. Tools, Toolings, Measuring devicesOld jigs, tools not in use are lyingModified tools, tooling for trial, are lying after trialWorn out items like bushes, liners, toggles etc. lyingBroken tools, bits, etc. may be lyingMeasuring equipment not required for the operationbeing performed , is l
11、ying 3. Contingency PartsMany times storage place for contingency parts becomea last refuge for broken parts, surplus items and thingsnobody is likely to use,Contd,S.B.Shinde - Sourcing Quality Assurance,Seiri = Sorting,Identifying unnecessary,4. Shelves and LockersShelves and lockers tends to colle
12、ct things that nobodyever uses , like surplus, broken items etc. 5. Passages and CornersDust, material not required seem to gather in corner 6. Besides Pillars and under the stairsThese places tends to collect junk, spittoon etc. 7. Walls and Bulletin BoardsOld out dated notices which have lost thei
13、r relevancePosters or bulletins on wallDust, remains of torn notices, cell tape pieces,Contd,S.B.Shinde - Sourcing Quality Assurance,Seiri = Sorting,Identifying unnecessary,8.Floor, Pits, PartitionsDefective partsProtection caps, coversPacking materialHardware items , small itemsEven tools, tooling
14、Items dropped on the floor are never picked 9.Computer Hard DiskMany unwanted, outdated, temporary files pile up,S.B.Shinde - Sourcing Quality Assurance,Seiri = Sorting,Improvement methods,1. Flow Process Chart (Procedural Analysis)Drawing a process flow chart for the systemeg. How to make and use c
15、ategory wise grouping2. Operational AnalysisPreparing the sequence of operations for system eg. How to perform Seiri (sorting)3. Check List A check sheet is used to decide what sort of main system and sub system are necessary.,S.B.Shinde - Sourcing Quality Assurance,Seiri = Sorting,Dealing with pape
16、rs,How to reduce papers onyour table ?,1. Make a single pile of papers 2. Go through them and sort infollowing categories,a) Immediate action b) Low priority c) Pending d) Reading material e) For information,S.B.Shinde - Sourcing Quality Assurance,Seiri = Sorting,Dealing with papers,How to reduce pa
17、pers onyour table ?,4 D PrincipleDO DELEGATE DELAY DUMP,S.B.Shinde - Sourcing Quality Assurance,SEITION = Systematic Arrangement,Meaning To determine type of storage and layout that will ensure easy accessibility for everyone .,Activity - Functional storage - Creating place for everything and puttin
18、g everything in its place,Success - Time saved in searching Indicator - Time saved in material handling,S.B.Shinde - Sourcing Quality Assurance,SEITION = Systematic Arrangement,The main target areas for Seri-Seiton improvement are :Tool-setting and preparation operations, line balancing and process
19、planning, parts supply to assembly line, peak time problems etc.Improvement Methods Kit Method / Assembly box method / Outside tool setting Cassettisation / Parallel operations / Changes in assignment method,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement,How to achieve Syste
20、matic Arrangement ?Decide where things belongDecide how things should be put awayObey the Put away rules,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement,How to achieve Systematic Arrangement ?Decide where things belong- Standardize Nomenclature- Determine an analytical method
21、 of storageDecide how things should be put away- Name & locations to everything. Label both item and location- Store material functionally- Prevent mistakes with coding by shapes & colourcontd,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement,How to achieve Systematic Arrangeme
22、nt ?Decide how things should be put away- Follow first in first out rule- If two identical items are to be located, then storethem separately, colour code them.Obey the rules- Put the things back to their location aftertheir use,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement
23、,USE :1 ) Signboards2) Colour codes3) Outline markings4) Labels,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement,Functional,Storage,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement,Usage Frequency,Store frequently used materialnear the workplace and less
24、 frequently at some distance,Weight & Shape of the Material,Heavy material should be storedat lower levels/layers Place directly on the materialhandling device for ease of handling,Functional Storage,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement,Category,Same category of ma
25、terial may be stored in one location. Eg. Allen Screws, Oil Seals,Operation Wise,All items required for an operation may be stored in onelocation.Eg. Allen key, spanner etc hand tools required for setting m/c,Functional Storage,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement,
26、Outlining and Placement Marks- Mark boundaries of dept., aisles, Machines- Follow straight line, right angle rule- Nothing shall be kept outside the boundariesStands and shelves- Keep only required number of stands and shelves- Standardize height, size- Provide casters where necessary so that it can
27、 bemoved,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement,Wires and Ducts- Colour code- When there are multiple connections - bundle thewires, label them and make sure that they are instraight line /right angle and firmly anchoredMachine-tools & Tools- Put the tools in the ord
28、er you need them- Location of the tool should be such that it can beput away with one hand- Try to eliminate some hand tools by permanentlyattaching it to the bolt head,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement,Blades, Dies, Other important consumables- Store them in th
29、e protected place- Maintain these things regularly by applying rustpreventive, oiling etc.WIP- Work In Process- Designate a place for each component/part- Decide on how much quantity to be stored- Ensure that there is no damage to good part during transit, they do not get rusty and they arenot misla
30、beled,S.B.Shinde - Sourcing Quality Assurance,Seiton = Systematic Arrangement,Oils- Reduce number of oils used (Standardize)- Colour code for oil- Safety aspects - fire prevention, pollution, leak,spillageInstrumentation & Measuring Devices- Label them, show direction of flow,S.B.Shinde - Sourcing Q
31、uality Assurance,SEISO = Cleaning,Meaning Cleaning trash, filth, dust and other foreign matter. Cleaning as a form of Inspection,Activity - Keep workplace spotlessly clean- Inspection while cleaning- Finding minor problems with cleaning inspection,Success - Reduction in machine down time Indicator -
32、 Reduction in no. of accidents,S.B.Shinde - Sourcing Quality Assurance,Seiso = Cleaning,Here cleaning means more than just keepingthings clean. Cleaning should be viewed as aform of Visual InspectionPreventive measures should be taken to tackleproblems of dust, grim, burrs, leakage etc.Root cause of
33、 the problem should be identifiedand it should be eliminated,S.B.Shinde - Sourcing Quality Assurance,Seiso = Cleaning,Various Minor Defects = Trash = Dirt =Knocking = Loose parts = Leaks =Scattering =Skips =Curvature =Abrasion =Rust =Scratches =Eccentricity =Lurching =Abnormal =VibrationMovements =A
34、bnormal =Heat =AbnormalSounds smells =Faded colour =Hisses,S.B.Shinde - Sourcing Quality Assurance,Seiso = Cleaning,5 Minutes Every day for cleaningDevote 5 minutes everyday for cleaning yourwork areaParticipation of everyone is requiredAttack hard to clean places regularly,S.B.Shinde - Sourcing Qua
35、lity Assurance,Seiso = Cleaning,Cleaning-Inspection points for mostequipment,Cleaning,Grime, clogging, dust balls, rust, leakage etc.,Oils,No oil, Low oil, leakage, filter clogging, dirty oil, dirty or bent oil lines, clogged drainage, oil spillage, worn& torn ports etc.,S.B.Shinde - Sourcing Qualit
36、y Assurance,Seiso = Cleaning,Cleaning-Inspection points for mostequipment,Tightening,Loose bolts, welding detachment, loose parts, vibration or bumping noise, friction,Heat,Oil tanks, motors, heater, axles, control panels, washing/ cleaning water, bearing, wiring etc.,S.B.Shinde - Sourcing Quality A
37、ssurance,Seiso = Cleaning,Cleaning-Inspection points for mostequipment,Breakage, Cracks,Breakage, cracks, dent on sliding parts, handle has come off, broken switches, wire joints come off, wires are broken or crack, crack dial of various pre. gauges, meters etc.,S.B.Shinde - Sourcing Quality Assuran
38、ce,Seiso = Cleaning,Function wise Cleaning check list ofequipment,Pneumatics,Hydraulics,Compressed Air lines, air valves,connections, meters, filters, reservoirs etc.,Hydraulic oil tank, oil valves, filters, pumps, hoses, gauges, cylinders etc.,S.B.Shinde - Sourcing Quality Assurance,Seiso = Cleanin
39、g,Function wise Cleaning check list ofequipment,Mech & Power Train,Electrical,Motor fan, fan belt, couplings, Joints, pulleys, chains, pump bearings etc.,Control panel, lamps, light, switch, sensors, wiring, ducts, fuses etc.,S.B.Shinde - Sourcing Quality Assurance,Seiso = Cleaning,Function wise Cle
40、aning check list ofequipment,Toolings,Equipment Specific,Tools, fixtures, gauges, dies, measuring instruments, etc.,Furnaces, rollers, chutes, CNC machines, etc.,S.B.Shinde - Sourcing Quality Assurance,SEIKETSU = Standardization,Meaning Setting up standards / Norms for a neat, clean, workplace and d
41、etails of how to maintain the norm (Procedure),Activity - Innovative visual management- Colour coding- Early detection of problem and early action,Success Increase in 5S indicator Indicator,S.B.Shinde - Sourcing Quality Assurance,SEIKETSU = Standardization,Tools used for analysis :MTTRMTBFOEE,S.B.Sh
42、inde - Sourcing Quality Assurance,Seiketsu = Standardization,Regularizing 5S activities so thatabnormalities are revealedMake it easy for everyone to identifythe state of normal or abnormalconditionFor maintaining previous 3S, deployvisual management,S.B.Shinde - Sourcing Quality Assurance,Seiketsu
43、= Standardization,It has been estimated by scientificstudy that 60% of all human activitiesstarts with sight5S is easy to do once.It is consistencythat is difficult. That is why VisualManagement is so important, so thateverybody will know that there is some problem.,Visual Management,S.B.Shinde - So
44、urcing Quality Assurance,Seiketsu = Standardization,What visual control communicates ?It grabs one or more of our senses in order toAlert us to an abnormalityHelp us recover quicklyPromote adherence and preventionEnable successful self management,S.B.Shinde - Sourcing Quality Assurance,Seiketsu = St
45、andardization,Some methods for visual communicationColour codingUse of LabelsDanger alertsIndication where things should be putDirectional arrows/ marksTransparent coversPerformance indicators,S.B.Shinde - Sourcing Quality Assurance,Seiketsu = Standardization,Some methods for visual communicationLab
46、elsPrecision management labelsInspection labelsTemperature labelsResponsibility labels,S.B.Shinde - Sourcing Quality Assurance,Seiketsu = Standardization,Points to remember in making visual c control tools 1. Make them easy to see from distance 2. Put the display on the things 3. Everyone can tell w
47、hat is right andwhat is wrong 4. Anybody can follow them and makenecessary corrections easily 5. Work place should look brighter &orderly,S.B.Shinde - Sourcing Quality Assurance,Seiketsu = Standardization,Some everyday visual management examples Traffic signalZebra crossingIn car - Petrol indicator-
48、 Speed indicatorDirection arrowsElectric danger sign etc.,S.B.Shinde - Sourcing Quality Assurance,Seiketsu = Standardization,Some visual communication signs,S.B.Shinde - Sourcing Quality Assurance,SHITSUKE = Self Discipline,Meaning Every one sticks to the rule and makes it a habit,Activity - Partici
49、pation of everyone in developing goodhabits- Regular audits and aiming for higher level,Success High employee morale Indicator Involvement of all people,S.B.Shinde - Sourcing Quality Assurance,SHITSUKE = Self Discipline,Activities : 5S Committee 5S Training 5S Competition / evaluation 5S Month Posters , Literature etc.,S.B.Shinde - Sourcing Quality Assurance,Shitsuke = Self Discipline,We need everyone to maintain 5S guidelines.To maintain DISCIPLINE, we need to practice and repeat until it becomes a way of life.Discipline is the Core of 5S,
