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IS A SCIENTIFIC APPROACH WHICH CAN BE APPLIED TO MANAGE/CONTROL/MAINTAIN AND IMPROVE HOUSEKEEPING PRACTICES WITHIN THE ORGANIZATION
SORT & DISCARD ARRANGE & LABEL CLEAN & WIPE MAINTAIN DISCIPLINE OURSELVES
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Objectives of 5S Program Achievement of systematic, y , organized workplace leading to visual management Building a good teamwork and communication. i ti p gp practical leadership p Developing and management skills . Developing Kaizen Kaizen-minded minded (continuous improvement)people at t the th workplace. k l
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5S?
THE IMPORTANCE OF 5S
Workplace W k l are clean l and d better b tt organized i d Visible result to ALL To enhance motivation & g generate ideas Improved discipline (SOP) Improved daily operation at shop floor /office. People will be proud of their workplace(ownership) Enhance Companys image
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A company that is implementing 5S successfully will improve towards: High Hi h i in Productivity P d ti it Consistent in Quality Cost-effective Accurate in Delivery Safe for people to work in High in Morale
5S?
The Three Different Types of Workplace A 3rd class workplace: has people who make a mess and no one cleans up up. A 2nd class workplace: has people who make a mess and another group of people clean up up. A 1st class workplace: has people who dont make a mess and yet everyone cleans up up.
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Shitsuke
Seiketsu Seiso
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1 2 3 4
Co Commitment e and a d suppo support by top op level management 5S education and training Participation by everybody Repeating the 5S cycle progressively to achieve a higher standard
Seiri is the sorting out and discarding of unnecessary items at the workplace.
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Which ???
Items Not Necessary
Stratification
Items having no value and easy to dispose Items having some value for sale
Items having no value but their disposal is costly
Required Action
Throw away immediately
Look for a buyer who offers the best price Work out a less costly and safe way for disposal Must be placed near the point of use Can be placed farther away Must be stored separately 11 with clear identification
SEIRI
Items frequently used
Items Necessary
For SEITON
Items sometimes used Items not used at all but must be kept
Why
Seiton is the arrangement of necessary items into good order so that they can be easily selected l t df for use.
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SEITON
Items Necessary
SEIRI
How to Seiton
SUPER
SEITON
A1
A1
A2
A2
A3
A3
A4
A4
A5
A5
A6
A6
A7
A7
B1
B1
B2
B2
B3
B3
B4
B4
B5
B5
B6
B6
B7
B7
C1
C2
C3
C4
C5
C6
C7
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C1 C2 C3 C4 C5 C6 C7
SUPER
SEITON
PD20
PD21
PD22
PD20
PD21
PD22
PD30
PD31
PD32
PD30
PD31
PD32
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SUPER
SEITON
B10-100
B12-100
B10-150
B12-150
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SUPER
SEITON
1 2 3 4 5 6 7 8 9 101112
SUPER
SEITON
B20S
B25S
B30S
B35S
B40S
B50S
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SUPER
SEITON
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10 11
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10 11 12
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SUPER
SEITON
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SUPER
SEITON
5 5 * 1 * 1
CLOSED 1 * 2 * 2 3 * 4 * 2 *
3 * 3
4 * 4
5 *
6 6 *
7 *
8 8 *
9 *
10 *
6 *
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8 *
9 9 *
10 10 *
11 * 11
12 * 12
13 *
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11 *
12 *
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16 * 16
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SUPER
SEITON
OFF
OFF
OFF
OFF
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SUPER
SEITON
A place for a kind Effective use of space p
CL10-40
CL15-20
CL20-20
BL20-50
BL20-20
BL30-20
BLH20-40 BLH20 40
BLH20-20 BLH20 20
BLH25-20
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SUPER
SEITON
COLD
HOT
COLD
HOT
Seiso is cleaning up ones workplace completely so that there is no rubbish/dust on floors, machines or equipment...
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Practice 5-10 minutes of Seiso daily. Assign an owner to each machine. Combine cleaning (Seiso) with inspection. p Repeat sweep-wipe-polishcheck-fix. h k fi Organize a Big Cleaning Day once or twice a year. How to Seiso
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Clean me !
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SUPER
SEISO
Prevent it from getting dirty Use o of t transparent a spa e t p plastic ast c dust co cover e
5S
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Seiri: Throw away things that are not needed and not being used used. Use space more economically(space is critically needed) Seiton: Improve locations and methods of storing g so that searching g and retrieval time is things minimized (time is precious). Seiso: Continue daily cleaning schedule to achieve a healthy and comfortable workplace. Togetherness with colleagues to come up with creative improvements at the workplace.
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Seiketsu is maintaining ones workplace so that it is productive and comfortable by repeating S iiS i Seiri-Seiton-Seiso. S i
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Shitsuke is training people to follow and instill good work habits by strict observation of workplace k l rules. l
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5S IMPLEMENTATION
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5S COMMITTEE
CHAIRMAN Derick
:B&P Area p + AKA Room :Workshop :Workshop + Overhaul Room :Parts Area + Meeting Room :Manager Room & Controller Room
:Admin Room + Prado Room :Reception p + Cust. Lounge g :RHS Workshop Compound :LHS Workshop Compound 37
5S ZONING
Paint Room B&P Room
B&P Area
Stockyard
Rubbish Damp
COMP
Electric
Overhaul Room
Tech. Room
Staffs Parking
Motorcycle Stand
Workshop
Car Wash Area
Parts Room
Controller Room
Manager Room
Customer Lounge
Admin
Parts Store
Reception
Prado
Customer Parking
Guard House
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A ti iti Activities
FEB
MARCH APRIL
MAY
JUNE
JULY
AUG
SEPT
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
1.0
Formation of 5S Committee. Inspection of Identified Zone and p g photos p or videos. capturing Big Cleaning Day.
2.0 3.0
DO
4.0
Mar
1-15th
5.0
Preparation of Results and Reports. 1st Internal Audit- Regional 5S Team investigate and reporting of Bad Environment
6.0
CHECK
7.0
Suggestion of Improvement and Report 1. Draft and apply countermeasures. 2 Second Internal Audit 2. Audit.
JuneAug
8.0
3.Finalised of SOP's at Regional Office (4th & 5th S, SEIKETSU & SHITSUKE) SOP 1 SOP 2 SOP3
ACTION
9.0
Establishing Standards.
Aug
10.0
Sept
REVIEW
11.0
39 Completed
Remark :
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WHAT WE CAN DO BEFORE BIG CLEANING DAY? PLAN WITH 5S TEAM TO IDENTIFY UNNECESSARY ITEMS & WHAT IS THE LABELLING PLAN?.. PREPARE EMPTY BOXES FOR SEIRI... SEIRI PREPARE LABELS AND IDENTIFY WHICH PRIORITY ITEMS TO BE LABELED... PREPARE CLEANING TOOLS... TOOLS ZONING AND APPOINT RESPONSIBILITY REFRESHMENT BUDGET... 43
WHAT WE CAN DO DURING BIG CLEANING DAY? START TO DISCARD ALL UNWANTED ITEMS.. ITEMS START TO SEITON..ARRANGE & LABEL THE IDENTIFIED NEEDED ITEMS.... CONDUCT INTENSIVE CLEANINGSEISO CLEANING SEISO MOVE.., ALLIGN.., LOOK FOR HIDDEN MESS..& CLEAR UP..!! EVERYBODY PARTICIPATES... PARTICIPATES
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5S IMPROVEMENT RECORDS
WORKPLACE
LOCATION NO.
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STEP 1
DATE
01/04/95
STEP 2
DATE
10/04/95
STEP 3
DATE
STEP 4
DATE
COMMENTS
COMMENTS
COMMENTS
COMMENTS
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5S IMPROVEMENT RECORDS
WORKPLACE LOCATION NO.
STEP 1
DATE
STEP 2
DATE
STEP 3
DATE
STEP 4
DATE
COMMENTS
COMMENTS
COMMENTS
COMMENTS
RATING
RATING
RATING
RATING
WORKPLACE
LOCATION NO.
STEP 1
DATE
STEP 2
DATE
STEP 3
DATE
STEP 4
DATE
COMMENTS
COMMENTS
COMMENTS
COMMENTS
RATING
RATING
RATING
RATING
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Seiri
Seiso
External Areas
Reception area
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Signboards Main entrance gate Guard house Landscape / compound Carparks Main entrance door Floors Walls, hanging posters Ceiling Lighting & switches Reception table Telephones C Computers t Printer Wire (telephones, PCs, etc) Chairs Files/documents/stationeries Cabinets/Racks Display & reading materials Waste baskets Bulletin board
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5S EVALUATION GUIDELINES
NO 1 Seiri CRITERIA Keep only necessary items 2 Seiton Assign items a place / location Arrange all items systematically. 5S STANDARD REQUIREMENTS To ensure there were no unnecessary items To remove unnecessary & old items. To ensure clearing of used parts, grease/oil and boxes etc. To ensure all items are located at it's designated places. To ensure the items are correctly placed in it's designated place. EXAMPLE OF ITEMS floors, tables, chairs posters, bulletin board floors at workshop tables, machines things at shelves, racks files, documents things at shelves, racks posters, bulletin board lighting & switches files, documents machines cabinet shelves shelves, racks floors at workshop
To ensure that all items are tidy and well-arranged. To ensure all items are arranged in order. To ensure items are hung in straight alignment & right angle. label all items systematically To ensure items are systematically labeled according to their location. and clearly. To ensure items are labeled for easy retrieval. To ensure items bear ID No. & names of person in charge (PIC). To ensure items bear on foreside names of contents & PIC. To ensure clear indication of the names of items stored. To ensure display of the names of person in charge. To ensure presence of lines/shapes drawn on the floor to indicate the places for keeping the equipments such as the floor jack, oil receiver etc. To ensure the presence of clearly demarcated lines on the floor. S Seiso i C t a clean Create l workplace k l T ensure items To it are clean l and d well-maintained. ll i t i d To ensure items are clean from dust and rubbish. To ensure items are clean and free from oil and grease. To ensure items are clean and present a good image. To ensure items are clean from cobweb, dirt and damage. Seiketsu Create the standards to follow To ensure unnecessary items are discarded and standardize the SOP SOP. To ensure items arranged & labeled and standardize the labeling. To ensure items are clean and fixed the SOP to maintain the cleanliness. To ensure availability of the standardized practice at all work area. To ensure clear display of standardized SOP for staffs to read & follow. y out enforcement / Diciplined. p To ensure availability y of evaluation schedule to maintain workplace. p Shitsuke Carry Re - train / follow up. To ensure appointment of 5S internal auditors/ evaluators. To check any presence of monitoring documentation to sustain the 5S activities.
service/working bay computers, t telephones t l h floors at office & showroom floors at workshop signboards, external area wall, windows, ceilings Seiri SOP SOP. Labeling code & SOP. SOP for floors cleaning. SOP at work areas. Proper displayed SOP etc. computers, p , telephones p floors at office & showroom floors at workshop
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TOYOTA
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CHAIRMAN RADZI
SECRETARY MUSLI
LEADER
: WAN
LEADER
: HASLIZA
TQM LAYOUT
P t Pantry Toilet
1
Hall Entrance
EAD
2
PH
Printer
CRM
WN USHA HI Co omputer room LAMP D - USHA E - MM / HI F - RR / ONG
St toreroom
MM KKF
5 3
RR ONG
G - CRM 94
TQM ZONING
EAD
Hall Entrance
ZONE 2 ZONE 1
CRM
Computer r room
ROUTINE 5S PROGRAM
1. Monthly 5S Meeting - ( Wed, 3.30 pm until 4.30 pm )
3. Daily 5S Activities
- 15 minutes Seiri, Seiton, Seiso before leaving g the office ( at the individual work place )
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WN
Completed
3 Cabinet Labelling
Office
UC/HI/WN
Completed
All
Completed
5 File Labeling
Office
UC/HI
In Progress
Store
OCW/RR
In Progress
PLAN
ACTUAL
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Store
HI/WN
In Progress
Distribute the balance of 2003 QCC Conv. Handout and Training Manuals.
Store
UC/MM
In Progress
Store
RR
In Progress
11 Decoration
Discussion Area
All
In Progress
Store Room
HI/WN
Plan
13 Switch Labeling
HI
Plan
All
Plan
PLAN
ACTUAL
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PHOTOS OF 5S ACTIVITIES
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CABINET
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RACKS
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RACKS (Cont.)
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SWITCHES
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FILES
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OTHERS
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OTHERS (Cont.)
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Some Issues/Problems faced by TQM Division 1 Sometimes 1. Sometimes, miss out daily and weekly 5S activity due to busy schedule. 2. Need time to prepare various labeling. 3. Need budget for purchasing some additional items. 4. Management of stock items is not systematically done. 5 Need to discipline strongly to instill the 5. habit of sitting together and discuss on 5S activities and follow up. 6. Need to remind each other on maintaining all the improvements that have been implemented.
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CONCLUSION
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5S
DAILY WORK
Carefully set up an effective 5S committee Ensure everyone to understand the philosophy and principles of 5S Brainstorm to diagnose the inconvenient disorganized or unsafe workplace Develop a plan/strategy for big cleaning day activity Prioritize the focus on critical areas e.g. eg pantry, toilet, garden, workshop bay, drainage system Self evaluate, benchmark & PDCA
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THANK YOU
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