Professional Documents
Culture Documents
NEW DELHI
Assignment On
Achieving
Quality With 5 S
AQM
“a place for everything and everything in its place.”
M.F.Tech – II (The source for the Japanese
characters is net1.ist.psu.edu/chu/wcm/5s/5s.htm,Nov 7, 2004)
Sem
Submitted By:
Harpreet Singh
(18)
Shweta Singh (28)
Introduction
(Ref: http/:www.kdr-associates.com)
technique for changing the mindset of the staff and involving the entire organization in
A simple yet powerful quality practice, 5S helps identify and eliminate waste in the
workplace. It also help establish and maintain a productive and quality environment in
The 5S concept was developed by Taiichi Ohno, who designed the Toyota Production
System and Shigeo Shingo, The Japanese practitioner who put forward the concept of
journey, typically they commence with 5S deployment and then move on to higher
methodologies. The idea behind 5S is that if a workplace is clean and well laid out, the
physical environment, but for improving thinking process as well. In this context, the
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executive.5S drive the necessary cognitive-behavioural process for the continuous
Through 5S the individuals rebuild their own workplace, which makes them able to
see changes occur, observe and reflect, and through their own actions they can adapt
new mental models for how things should be done. So 5S should not only be focused
principles that can help to focus, analyse and manages any aspect, task or problem
both in the individual and in the organizational context. From this consideration we
can introduce the criteria that 5S is a tool to separate untidiness and disorder from the
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5S Steps Defined:
• Seiri- Sorting Out: Remove what is not needed and keep what is needed.
• Seiton- Set In Order: Place the things in such away that they can be easily
• Seiso- Shining: Keep things clean and polished; no trash or dirt in workplace.
cleaning.
undertaking to inspire pride and adherence to standards established for the above
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1st S – SEIRI - Sorting Out
The first S, Seiri,calls for the elimination of unnecessary items that have collected
around work areas. As debris and unused objects build up, productivity often takes a
turn for the worse. In unproductive workspaces, frustrations mount when workers find
that they are unable to satisfactorily finish the task at hand. Therefore, it is vital to
The effective visual method of identifying unneeded items is called “Red Tagging”. In
Be sure to use separate labels to indicate potentially hazardous materials. After the
unused items are gathered, they should be moved to a well-identified collection area
(RED TAG AREA) that has been specifically established for this purpose. Be sure to
use clearly visible labels and signs to make the purpose of this area clear. Signs
should describe the process of turning in items for collection. Once these “red tag” or
unused items, are brought to the collection area, perform an evaluation. Items that are
potentially useful may be subsequently labeled for cleaning and storage, while tools or
implements that have reached their end-of-life point should be discarded immediately.
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SEIRI-Conclusion
With the completion of the first S, Sorting, three main results are obtained:
2. Workers will be more satisfied with their environment – Employee morale would
increase as junk items or materials that are potential health hazards are identified and
removed.
3. The end product of your labors will be much improved as full attention can be paid
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2nd S – SEITON - Set in Order
Seiton involves determining a defined place for every tool, bin, pallet, supply, material,
and even work order papers so that anyone can find the items easily and put them
back where they belong after using them. Items in the workplace are labeled
according to their use. Then a 5S map showing the current locations of parts, jigs,
tools, equipment, and machinery is developed, the location of each item is evaluated,
and the best location determined. Finally, shadow boards are developed to display
with the end goal of developing an environment that resists clutter and aids long-term
If tools and materials are excessive, return to the first S, Sorts and remove unused
items to a location more suitable for long-term storage. Once we have identified our
most commonly used tools and materials, find an accessible location for them. If this
tool storage area is located at some distance from our actual work location, consider
1. Marking spaces & installing modular shelving & cabinets. Floor markings are
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2. In workspaces with extensive interior wall space, signs and labels should be used
to help orient workers and assist workflow. For example, small overhead maps (“You
are here”) and legends can be printed on both labels and signs, and affixed to walls.
since they may be neglected for long periods of time. In many cases, it is appropriate
to affix RTK (Right to Know) labels for other warning labels to containers used in
storage areas.
It is also important to consider installing shelving and cabinets that are easily
customizable.
SEITON – Conclusion
The first two S’s (Sort and Set in Order) provide a strong foundation for a workplace
driven not only by skills and labor but also by the values of organization and simplicity.
Though extra discipline is necessary at first, these habits will begin in pay dividends
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3rd S – SEISO – Shine - Spic & Span
Seiso involves ensuring that everything in the factory stays clean through preventive
initiatives and cleaning routines. The idea is to keep everything swept and clean.
Visual and physical cleaning activities are developed to show the frequency and
responsibility for individual and common areas, such as cleaning the sanding table
filter, emptying the trash can, changing spray booth filters, and putting away
to thoroughly clean that area and the equipment in it. Leaks, squeals and vibrations
involving clean equipment can often be easily detected, but a dirty workplace tends to
be distracting and equipment faults go unnoticed. Clean workplace conditions are also
important to employee health, morale, and safety. These factors add up to impact
During the initial cleaning, employees will notice areas that seem to especially attract
garbage or spills. It is important to make a note of these areas. After the cleaning is
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3. Take steps necessary to ensure that the problem will not persist in the future.
In this way, a little effort in the beginning will reduce the necessity of deep cleaning
later. We must Make sure to evaluate the facility’s ability to keep clean.
2. Are cleaning supplies replenished and marked with instructions for use?
3. Are there enough waste receptacles, and are they clearly labeled?
After the first cleaning it is important to look for areas that are still dingy or dirty. This
may indicate that you need stronger cleaning solvents or tools. Cleaning operations
can coincide with equipment evaluations in order to ensure that proper care and
maintenance is observed. As employees clean their work areas, they will become
familiar with the basic functions of the equipment around them and will enjoy greater
SEISO – Conclusion
The benefits of a clean workplace are readily apparent after a short period of time.
Employee morale increases, and the most productive time can be dedicated to the
most important tasks. Considering the short amount of time required, the results of a
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Seiketsu involves applying standard operational procedures, best business practices,
achieved by the first three steps. Standardizing helps ensure that everyone in the
organization knows the expectations. It makes standards visible so that variations can
standards tend to lose effectiveness with time. The employees must be allowed to
Keep employees informed by making the standards visible. Use customized posters,
Standards offer employees and employers a way to reach common goals while
displayed around the workplace using signs and posters. Labels can also be used as
aids in quick reference to 5S-related materials. For example, areas containing many
As the employees adjust themselves to this new environment, We make sure that the
standards are easy to understand and offered in multiple languages where necessary.
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SEIKETSU – Conclusion
production goals.
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maintain the working environment that has been developed. At this point, the success
achieve. People tend to resist change and even the most well structured 5S plan will
fail if not constantly reinforced. Fortunately, there are effective methods of sustaining
3. What tools and resources are available to help measure this progress and sustain
growth?
We will also find that employees benefit by easy access to label and sign-making
systems. With the ability to print visual materials on demand, most any employee can
Finally, look for ways to emphasize the positive results of a 5S program. Catch
phrases and slogans can be used to make sure no one forgets the significance of
goals.
SHITSUKE – Conclusion
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Sustaining newly changed behavior is not easy. However, the results are rewarding
for everyone involved. As employees grow into the 5S system, the will find it
energizing and fulfilling. We must ensure to go the extra mile to make sure our
Excess inventory.
OVERCOMING RESISTANCE:
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The 5S initiative starts with top management and trickles down to shop floor and office
personnel. People will offer excuses why they cannot participate in the implementation
and execution of a 5S program. To achieve the benefits of 5S, the organization must
• “We are paid to produce, not to clean up.”Managers need to build time into
production schedules for 5S activities and communicate that to employees. (It will
• “Why clean it? It will just get dirty again.” Sometimes people accept dirtiness as an
inevitable workplace condition. On the other hand, you need to know what the
benchmark is.
• “I’m too busy working on 5S activities.” Some activities can be put off, but as with
cleaning your dishes or changing the filter in your home heating system, negative
• “We did 5S years ago.” A 5S initiative is not a passing fashion. It fosters all types of
improvements. Such negative comments are typical when a new program is being
explain the benefits of 5S for both the company and its workforce and to provide
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solutions to the problems. Top management commitment is needed to ensure
program and which role each individual plays in the program’s overall success.
well-implemented 5S program helps the culture develop a new sense of discipline and
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Implementing 5S methods in the plant would help the company to reduce waste
hidden in the plant, improve the levels of quality and safety, reduce the lead time
and cost, and thus, increase company's profit. The potential benefits of 5S can
Five English S:
PQCDS:
• P - Increase productivity.
Certification
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Training in 5S is provided by several consulting firms . One will receive a certificate
when completing the training. Furthermore, some countries have created their own
National Productivity and Competitiveness Council which in turn introduced the so-
1) A team of 5 auditors will audit the workplace proposed for certification. Three
3) Following three random audits and on the basis of the auditors report, eligibility of
implemented 5S practices.
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SCORE ACHIEVEMENT CURVE—1 YEAR AFTER 5S BEGINS
habits. It can apply in personal life, home life and social life. Supporters of 5S believe
that when one is self-disciplined, it will improve the way he / she tackles personal
a backbone of other management philosophies. It grows from individual level and then
expands to organizational level. When the individual performs well, it will also create
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an influential impact to his / her peers. Alongside with encouragement and recognition,
management can easily promote expected behaviors from staff. On the other hand,
employees have a better idea of what they need to achieve to demonstrate their
competencies.
In brief, the 5S theory supports and maintains the performance management system.
(Ref:http://www.envision-hc.com)
CASE STUDIES
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The Leisureline Case Study
The Company
Leisureline (Pvt) Ltd, Sri Lanka is a small company situated in the Free Trade Zone in
labels like Victoria's Secret, Gap, Vanity Fair, Triumph, Hanro, Marks & Spencer, Bhs, C&A,
Challenges
Established in 1998, Leisureline (Pvt) Ltd turned the factory into a profit making
time Sylvie-Honor (Pvt) Ltd was bought over by the MAS Group, the workforce
had been de-motivated and used on an ad hoc basis. The move was a challenge
to the MAS Group, which had never bought an existing factory with unskilled and
de-motivated labour. The core issues before the new management had been the
need to bring together the various levels of employees and making them
understand the skills and competence required to run a world-class factory. This
has been an extremely difficult task because most of the machine operators had
been unaware of the need to be efficient, accurate and methodical at the same
time.
Another challenge for the company had been to convince the employees of Sylvie-
Honor that they would be absorbed direct into the new company.
5S system
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One of the secrets behind Leisureline's success is the company's strict
effort, time and money while enhancing the value of outputs and improving
employee morale.
The last five minutes of every working day are spent on arranging the workplace
while a special 5S song is played. Twice a year, on July 31st and December
31st, all employees including the management get special time to clean their
A number of teams have been appointed to look into matters like food and
parking. And every new employee recruited by the company is first introduced to
the 5S concept because competitions are held often to award the best team that
cost of capital
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Frequent internal audits are done within the company in order to
results.
Problems Identified
margin.
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• There is a seasonal trend in the business, with the busy period being
areas.
Recommendation:
• Use value stream mapping to identify “waste” within the operation. This
will enable a
• Consider the need for annualised hours to cope with the seasonal
variances in
• demand. (This may not be necessary if the lead time can be reduced).
stream”,
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• Implementation of improvement took place over next four month.
• 5S was implemented.
• Internal audits are done to see whether the company is complying the
5S. (The format of the audit form can be referred from Sheet-2
Results:
• 2 jobs safeguarded
Bibliography:
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• http://www.envision-hc.com[Assesed on 07 Apr’09]
• Hirano, Hiroyuki and Dr. J.T. Black. 1988. JIT Factory Revolution. Cambridge.
Productivity Press
• http://www.businessknowledgesource.com/manufacturing/the_5_s_appro
ach_to_lean_manufacturing_extended_entry_026157.html [Assesed on
20 Apr’09]
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