1、1,TRAINING SESSION,ON,5 S,5 S,2,What is 5 S ? 什么是5S,5 S is a participation program. 5S是一个全员参与的项目It is a very effective approach to improving our work environment and total quality。是一个非常有效地改进我们工作环境和总体质量的方法It becomes a base for continuous improvement in the organization. 是在组织内实现持续改进的基础。,3,Why 5S is wi
2、dely used 为何5S被广泛地应用,Work place becomes clean and better organized. 工作场所变得更清洁和更易于组织管理。Shop floor and office operation become easier and safer. 工场的地面和办公室运作变得更容易和安全。Results are visible to everyone , insider and outsider. 每个内部或外部的人都可以直观地看到结果。Visible results enhance generation of more and new ideas. 可视的
3、效果激发了更多的新的思路的产生。People are automatically disciplined. 人们自觉地遵守纪律。People become proud of clean and organized work place. 清洁和有组织的工作场所使人们变得自豪。Resultant good company image generates more business etc 具有良好形象的公司会带来更多的业务。,4,6 objectives of 5S Program 5S项目的6个目标,A clean workplace is high in PRODUCTIVITY 一个清洁的
4、工作场所代表高的生产力 A clean workplace is high Quality 一个清洁的工作场所代表高的质量 A clean workplace keeps COST Down. 一个清洁的工作场所能保持成本的不断降低。,5,6 objectives of 5S Program 5S项目的6个目标,A clean workplace ensures Delivery on time 一个清洁的工作场所有助于确保交付的准时. A clean workplace is SAFE for people to work 一个清洁的工作场所对工作人员是安全的. A clean workpl
5、ace is high in MORALE一个清洁的工作场所有助于工作士气的高昂。,6,What are 5Ss? 5S中的“S”代表什么?,1. SEIRI : Sort - out unnecessary items in the work-place and discard them清理:将不必要的物品从工作场所清走并丢弃它们。2. SEITON: Arrange necessary items in good order so that they can be easily picked for use 整顿:将必需的物品按规定的位置存放，以便能容易地找到并使用。3. SEISO: C
6、lean your workplace completely so that there is no dust on floor, machine and equipment清扫:彻底地打扫您的工作场所，保证在地板，机器和仪器上没有灰尘。4. SEIKETSU: Maintain high standard of housekeeping & workplace organization at all times清洁: 始终高标准地维护房屋的干净和工作场所的整洁。5. SHITSUKE:Train people to follow good housekeeping Disciplines素养
7、:教育人们遵守良好的保洁纪律。,7,Step-1,Look around you. .看看您的周围 Are there things not of use any more?.yes. 有不经常使用的东西吗?有. Outdated diaries, pens run out of ink, tools 过时的日记,没有墨水的笔,工具 which are broken and useless, Files which arenever referred to, 哪一个是破损的和无用的,从没有用过的文件 Throw these away IMMEDIATELY. 立即扔掉它.,8,Step-2,F
8、irst decide which things to be put where. 首先决定哪一东西放在什么地方- Those which you need very often in your job should be placed very near to your workstation 其中哪些是您在工作中非常需要的,将它定置于 距您工作站最近的地方. Things not used often could be placed away 如果不是使用频繁的物品，可以放得远一些. Keep a list of things with their location. 在保存的地方存放一个
9、物品的清单.,9,Step-3,Do not wait for things to get dirty before you clean them. Clean regularly 不要等到东西脏了才去清扫,要定期地做. Put aside 3 minutes every day to clean your workplace 每天保持3分钟用于打扫您的工作场所. Never throw anything around or dirty any place. 不随意向周围丢东西和将弄脏任何地方. Regularly clean the machines & tools. 定期地打扫机器和工具.
10、,10,Step-4,If you do not consciously try to maintain the clean environment, very soon you will find that your workplace is dirty again. 如果您不是自觉地保持清洁的环境,您将会很快 地发现您的工作场所又变得脏乱. Make schedule for cleaning and organizing your workplace. 给整理和清洁您的工作场所制定计划. Inter departmental competitions on housekeeping 在日
11、常保洁中进行内部竞赛.,11,Step-5,Management should train its staff and try to develop a culture within the company where by good housekeeping becomes every bodys habit 管理者要培训员工,努力在公司内部形成一种 文化,使良好的日常保持成为每人的习惯.Treat your workplace as the second home. 将您的工作场所看作第二个家.Maintain your attitudes and habits. 保持您的态度和习惯.,1
12、2,Some significant benefits observed 一些可见的重要效果,Happier Employee with high morale 具有高昴士气的快乐的员工Greater people involvement 大量的人员参与.Low Employee turnover 低的员工流动.Increased number of suggestions 建议数量的增加.Better use of floor space 更好地使用空间.Less work-in-progress and inventories少的在制品和库存.Better flow of work. 更好
13、的工作流程.Low machine breakdown rates.低的设备停机率.Low accident rates.低的意外事故率.High yield of materials高的产出率.High product quality 高的产品质量.,13,Part 1 - What is 5 S,Part 2 - How To Implement 5 S,5 S,第一部分：什么是5S,第二部分：如何实施5S,14,Part 1 - What is 5 S,5 S,第一部分：什么是5S,15,Quality Improvements 质量改进,5 S,16,Impact Of 5 S At
14、The Workplace,Equipments,Material,Jigs / Tools,Methods,Workers,Products,Timeliness,Maintains,Ensures Max. Utilization,Upkeeps,Improves,Motivates,Ensures Good,Promotes,RESULTS IN,QUALITY质量,SAFETY安全,EFFICIENCY效率,CONTROL控制,CUSTOMER SATISFACTION客户满意,EMPLOYEE SATISFACTION员工满意,5 S,在工作场所实施5S,17,What are th
15、e 5 Ss 5S中的“S”代表什么?,Seiri - Sorting 整理(分类) Seiton - Systematic Arrangement整顿(系统安排) Seiso - Cleaning 清扫 Seiketsu - Standardization清洁(标准化) Shitsuke - Training & Discipline 素养 (培训和纪律),5 S,18,SEIRI,分类,5 S,整理,( SORTING ),19,Seiri - Sorting 整 理,SEIRI - SORTING,TO CLEARLY DIVIDE OBJECTS INTO TWO GROUPS 明确地
16、区分两组不同的物体. - THOSE ITEMS THAT ARE NECESSARY. 这些项目是必需的. - AND THOSE ITEMS THAT ARE NOT NECESSARY. 这些物品不是必需的.,TO GET RID OF THE UNNECESSARY去掉不需要的. AND TO KEEP THE NECESSARY保存必要的.,5 S,20,1. Item is not needed 物品不是必需的. 2. Item is needed however quantity in stock is more than what is needed for consumpti
17、on in near future 物品是需要的,但是贮存的比实际消耗的多 3. Contingency Parts 偶然使用的部件(應急零件)Critically decide the quantity of contingency parts to be retained and criteria for such parts 精确地确定急需部件的数量并按标准保存它们。,What is unnecessary 什么是多余的?,5 S,Seiri - Sorting 整 理,21,Frequency of use 使用的频率,Storage Method 贮存的方法,Organization
18、 组织,Seiri - Sorting,5 S,22,Identifying unnecessary 确定不必要的,1. Parts & Work in Process (WIP) 在流程中的部件和工作Things fallen back behind the machine or rolled under it掉落在機器後面或滾入機器中的部件Broken items inside the machine 设备内部破损的部件Things under the racks/ platform在架子或工作台下面的物品Extra WIP 额外的在制品Stock of rejected items 拒收
19、物品的贮存Items accumulated over period for rework堆积的过期的返工物品Material awaiting disposal decision 等待处理的材料Material brought for some trial, still lying even after trial 用以试验甚至已经完成试验的材料Small qty of material no longer in use 不會再用到的小批量材料,Seiri - Sorting 整理,5 S,Contd,23,Identifying unnecessary 确定不必要的,2. Tools, T
20、oolings, Measuring devices 工具,工装,测量装置Old jigs, tools not in use are lying(舊的工夾具、工裝不再使用的已躺下的)Modified tools, tooling for trial, are lying after trial(修改過的工裝，試驗的工裝，經過試驗後躺下的)Worn out items like bushes, liners, toggles etc. lying(用舊的項目例如襯套、襯墊、套索釘等躺下的)Broken tools, bits, etc. may be lying(損壞的工裝、墊片等)Measu
21、ring equipment not required for the operation(不需要再使用的測量設備)being performed , is lying 3. Contingency Parts偶尔使用的部件Many times storage place for contingency parts becomea last refuge for broken parts, surplus items and thingsnobody is likely to use,Contd,5 S,Seiri - Sorting 整理,24,Identifying unnecessary
22、 确定不必要的,4. Shelves and Lockers 架子和带锁柜子Shelves and lockers tends to collect things that nobodyever uses , like surplus, broken items etc. 5. Passages and Corners 通道和角落Dust, material not required seem to gather in corner 6. Besides Pillars and under the stairs柱子旁和楼梯下These places tends to collect junk,
23、 spittoon etc. 7. Walls and Bulletin Boards围墙和公告栏Old out dated notices which have lost their relevancePosters or bulletins on wallDust, remains of torn notices, cell tape pieces,Contd,5 S,Seiri - Sorting 整理,25,Identifying unnecessary确定不需要的,8.Floor, Pits, Partitions 地面，凹坑，隔离物Defective partsProtection
24、 caps, coversPacking materialHardware items , small itemsEven tools, tooling Items dropped on the floor are never picked 9.Computer Hard Disk 电脑的硬盘Many unwanted, outdated, temporary files pile up,5 S,Seiri - Sorting 整理,26,Seiton - Systematic Arrangement系统安排,SEITON 整顿,5 S,27,A Place for Everything,An
25、d Everything in its Place,Seiton - Systematic Arrangement系统安排,每件东西都有规定的地方,每件东西都在规定的位置上,28,How to achieve Systematic Arrangement ? 怎样实现系统的安排?Decide where things belong确定物品的归属.Decide how things should be put away确定怎样贮存物品.Obey the Put away rules 遵守存放规则 .,5 S,Seiton - Systematic Arrangement系统安排,29,How t
26、o achieve Systematic Arrangement ? 怎样实现系统的安排?Decide where things belong 确定归属- Standardize Nomenclature标准化相关术语.- Determine an analytical method of storage确定贮存的分析方法.Decide how things should be put away 确定如何存放- Name & locations to everything. Label both item and location对每一件物品命名和定置. 标明项目和位置.- Store mat
27、erial functionally存贮材料的功能.- Prevent mistakes with coding by shapes & colour通过形状和颜色的标识来防止错误.contd,5 S,Seiton - Systematic Arrangement系统安排,30,How to achieve Systematic Arrangement ? 怎样实现系统的安排?Decide how things should be put away 确定物品应怎样保存- Follow first in first out rule遵守先进先出的原则.- If two identical ite
28、ms are to be located, then store them separately, colour code them.如果两个同样的物品被定置,贮存时要用颜色或代码区分它们Obey the rules 服从规则- Put the things back to their location after their use 将使用后的东西放回它们固定的位置.,5 S,Seiton - Systematic Arrangement系统安排,31,USE :1 ) Signboards 布告板2) Colour codes 彩色代码3) Outline markings 不同形状的标识
29、4) Labels 标签,5 S,Seiton - Systematic Arrangement系统安排,32,Functional功能,Storage 贮存,5 S,Seiton - Systematic Arrangement系统安排,33,Usage Frequency 使用频率,Store frequently used material near the workplace and less frequently at some distance经常使用的材料靠近工作点，不经常使用的在远一些的地方。,Weight & Shape of the Material 材料的重量 和形状,H
30、eavy material should be storedat lower levels/layers Place directly on the material handling device for ease of handling 重的材料贮存在低的地方以便容易处理.,Functional Storage 功能贮存,5 S,Seiton - Systematic Arrangement系统安排,34,Category 种类,Same category of material may be stored in one location. Eg. Allen Screws, Oil Se
31、als 一些种类的材料可以贮存在一个地点.如坚固类的螺丝类、密封件类等。,Operation Wise 操作技巧,All items required for an operation may be stored in one location.Eg. Allen key, spanner etc hand tools required for setting m/c 和某个操作有关的所有物品可以贮存在一个地方。例如：,Functional Storage 功能贮存,5 S,Seiton - Systematic Arrangement系统安排,35,Outlining and Placeme
32、nt Marks 不同形状的标识及布置- Mark boundaries of dept, aisles, Machines部门、过道、机器间划出分界线。- Follow straight line, right angle rule 按照直线和正确的角度规则摆放- Nothing shall be kept outside the boundaries 保持任何东西都不超越边界。 Stands and shelves工作台、架- Keep only required number of stands and shelves 仅保存必须数量的工作台、架。- Standardize height
33、, size 使高度和大小标准化- Provide casters where necessary so that it can be moved最好备有轮子以便当需要时可以移动。,5 S,Seiton - Systematic Arrangement系统安排,36,Wires and Ducts线路和管路- Colour code 彩色的编码- When there are multiple connections - bundle the wires, label them and make sure that they are in straight line /right angle
34、and firmly anchored在布置多线路时：应将线捆扎，给它们贴上标签，确保它们一直线上或在正确的角度上并且使它们固定。Machine-tools & Tools设备的工具和工装- Put the tools in the order you need them将工具按你要求的顺序排列.- Location of the tool should be such that it can be put away with one hand工具应定置于一个人伸手就能拿到的位置。- Try to eliminate some hand tools by permanently attachi
35、ng it to the bolt head,5 S,Seiton - Systematic Arrangement系统安排,37,Blades, Dies, Other important consumables 刀片、模具和其它重要的消耗品 - Store them in the protected place 将它们贮存在安全的地方。- Maintain these things regularly by applying rustpreventive, oiling etc.应用防锈，加油等办法定期地维护它们。WIP- Work In Process 在制品- Designate a
36、place for each component/part 给每一个零件或部件找一个地方- Decide on how much quantity to be stored 决定需要贮存多少数量。- Ensure that there is no damage to good part during transit, they do notget rusty and they are not mislabeled。确保完好的部件在运输中没有被损坏、没有生锈和没有贴错标签。,5 S,Seiton - Systematic Arrangement系统安排,38,Oils 油类- Reduce nu
37、mber of oils used (Standardize) 减少使用油的数量- Colour code for oil 给油品做彩色的编码- Safety aspects - fire prevention, pollution, leak,spillage 安全方面防止着火，污染，泄漏和溢出。Instrumentation & Measuring Devices 仪器和测量装置- Label them, show direction of flow标识并指出使用的去向。,5 S,Seiton - Systematic Arrangement系统安排,39,Seiso,( Cleaning
38、 ),5 S,清扫,40,Seiso - Cleaning 清扫,Activity - Keep workplace spotlessly clean 保持工作场所没有污点- Inspection while cleaning 边清洁边检查- Finding minor problems with cleaning inspection 借助清洁检查发现小问题,Success - Reduction in machine down timeIndicator 减少停机成功的 - Reduction in no. of accidents指标 减少事故,Seiso -,Clean workpla
39、ce completely so that there is no dust on the floor, machines and Equipments彻底地清扫工作场所，保证在地面，机器上和周围环境中没有灰尘。,5 S,清扫,41,While Cleaning up and getting rid of dirt and unclear items potential defects such as Abrasion, Damage, Loose Parts, Deformities, Leaks, Vibration, Abnormal Sound etc., are revealed a
40、nd hence Seiso is inspection 当清扫干净、去掉污垢后，不清楚的潜在缺陷项目如：磨损、破损、部件松动、变形、泄漏、振动、异常的声响等被显露。因此，清扫是检查。,5 S,Seiso - Cleaning 清扫,42,Here cleaning means more than just keeping things clean. Cleaning should be viewed as a form of Visual Inspection 这里的清扫的意义不仅是保持物品的干净，而应是以目视检查的形式观察。Preventive measures should be tak
41、en to tackle problems of dust, grim, burrs, leakage etc. Root cause of the problem should be identified and it should be eliminated 预防的措施应该被采用如工具的灰尘、粗糙、异响、泄漏等问题的根本原因应该被识别和被消除。,5 S,Seiso - Cleaning 清扫,43,5 Minutes Every day for cleaning每天用5分钟打扫卫生 Devote 5 minutes everyday for cleaning yourwork area 每
42、天投入5分钟用于您的工作场所的清洁Participation of everyone is required要求每个人都参加。Attack hard to clean places regularly 有规律地突击难点。,5 S,Seiso - Cleaning 清扫,44,Cleaning-Inspection points for mostequipment 清扫检查更多是针对设备,Tightening拧紧,Loose bolts, welding detachment, loose parts, vibration or bumping noise, friction 松动的螺栓、焊缝、
43、松动的部件或振动的 噪声、磨擦。,Heat,Oil tanks, motors, heater, axles, control panels, washing/ cleaning water, bearing, wiring etc. 油桶、发动机、加热器、轴类、控制板、冲/洗 用的水、轴承、配线等。,5 S,Seiso - Cleaning 清扫,45,Cleaning-Inspection points for mostequipment 清扫检查更多是针对设备,Breakage, Cracks 破损和裂纹,Breakage, cracks, dent on sliding parts,
44、handle has come off, broken switches, wire joints come off, wires are broken or crack, crack dial of various pre. gauges, meters etc. 破损、裂纹、滑行部件的凹凸不平、手柄脱落、开关损坏或开裂、标准尺和米尺等不同刻盘的破损。,5 S,Seiso - Cleaning 清扫,46,Seiketsu,( Standardisation ),5 S,标准化,清洁,47,Activity - Innovative visual management 创建目视管理- Col
45、our coding 彩色的编码- Early detection of problem and early action尽早地发现问题和尽早地行动。,Success - Increase in 5S indicator Indicator 增加5S的标识,Seiketsu -,清洁标准化,Setting up Standards / Norms for a Neat & Clean workplace and details of how to maintain the Norms (Procedure) 对一个整洁的或清洁的工作场所建立标准或规范及怎样保持的详细资料（程序）,5 S,Sei
46、ketsu - Standardisation,48,Seiketsu - Standardisation,Maintain & Improve The Standards of : * Seiri* Seiton* Seiso,5 S,维护和改进 整理、整顿、清扫的标准,清洁标准化,49,Regularizing 5S activities so that abnormalities are revealed 有规则地5S活动使异常被显示。 Make it easy for everyone to identifythe state of normal or abnormalconditio
47、n 使每个人都可以容易地识别正常的或异常的状态。For maintaining previous 3S, deployvisual management 对保持以前的3S，要配置目视管理。,Seiketsu - Standardisation,5 S,清洁标准化,50,It has been estimated by scientific study that 60% of all human activities starts with sight通过科学的研究表明：人类活动中60是从视觉开始的。5S is easy to do once.It is consistency that is
48、difficult. That is why Visual Management is so important, so that everybody will know that there is some problem. 做一次5S是容易的。持续地保持它是困难的。这就是为什么目视的管理如此重要，以致于每个人都能知道问题的存在。,Visual Management 目视管理,Seiketsu - Standardisation,5 S,清洁标准化,51,What visual control communicates ? 什么是目视控制的信息交流？ It grabs one or more of our senses in order to 可以从中获得一个或更多的感受用以：Alert us to an abnormality 提醒我们有异常Help us recover quickly 帮助我们快速地恢复正常Promote adherence and prevention 促进坚持和预防Enable successful self management 使自我管理获得成功,
