Welcome to 5S Presentation

Gayathri Lean consultancy

Service offered:
Training & Hands hold implementation support
1. Lean manufacturing techniques
2. TPM (Total productive maintenance)
3. Job method for Assembly operation
4. Micro motion study for Assembly & Robotic operation
5. Dust reduction in painting parts – Robotic and manual spray paint shops

gayathri.leanconsultancy@gmail.com
Contact: 9786257107, 7010378025
Pondicherry –India
1 S,
2 S,
3 S,
4 S,
5 S.
1 Sorting Out. 5 S
2 Systematic Arrangement.
3 Shine Everything.
4 Standardization.
5 Self Discipline.
 5 ‘S’ & It’s Benefits
Topic Understanding Actions to be taken Benefits

1 ‘S’ Sorting Out • Segregate Wanted & Un-Wanted things . Space Saving & Improvement
• Remove Un-Wanted ones. in Work Efficiency .
• Decide on frequency of sorting.

2 ‘S’ Systematic • Decide the Place & Arranging in order.

• A place for every thing and every thing in Search Time reduced.
Arrangement it’s place.

3 ‘S’ Shine Everything •Dust Free Equipment / Work Place. •Healthy Work environment
(Cleaning) • Make it easy to Clean. •Abnormalities are Visible
• Make it easy to Inspect Abnormalities. & Corrected.

4 ‘S’ Standardization •Standard Procedure for all activities. Achieving Higher Productivity
•Review of Procedures and Work and Better Quality.
Instructions at a Fixed Interval.

5 ‘S’ Self Discipline • Forming the Habit / Culture. •Habit of doing it Right
• Regular Training & Update. First Time and Every Time .
• Follow the decided things. Total Employees
Involvement.
1Sorting out :

Sort & Out

What to Sort & What to
send Out ( REMOVE ) ?
1Sorting out :
Sorting:
Identify,Segregate
Wanted & Unwanted things
1Sorting out :
out (REMOVE):
RE - MOVE Unwanted things
to
RED TAG AREA
 RED TAG AREA
‘Red Tag Area’ is a designated place
at all respective zones (Production
/ Non production) where unwanted
things can be collected temporarily
and finally removed.
1 Sorting out

RED
TAG AREA

Removal of unwanted things

 1Sorting out :
ORGANIZATION CHART FOR '5S' TEAM

CEO
Team members
5S' COMITTEE are operators
COORDINATOR

DEPUTY
COORDINATOR

ZONE-1 ZONE-2 ZONE-3 ZONE-4 ZONE-5 ZONE-6 ZONE-7

TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER TEAM LEADER

TEAM TEAM TEAM TEAM TEAM TEAM TEAM

MEMEBERS MEMEBERS MEMEBERS MEMEBERS MEMEBERS MEMEBERS MEMEBERS
Make zones by allocating a reasonable area
to each leader
2S (Systematic Arrangement)

Objective
•Place for Every Useful Thing & Every Useful Thing is
on it’s place .
•Arranging them in a Systematic manner.

Result: Reduces Search Time

2S (Systematic Arrangement)

Methodology to Implement ‘2S’

•Check What (Item Identification)?, Where ( Location)?
& How Much ( Quantity)? When ( Time limit)? Before
actually practicing ‘2S’.
•Decide appropriate location for every thing.
•Display identification mark for every location.
•Items stored should have the Identification Mark including
purpose of storage & its review date.
2S

Right Things in the Right Place.

 (Systematic Arrangements)
2 S Before After
2S
Search
Time
Elimination
Fan &
Electrical
Switches
Identified
2S ‘2S’ in Office
• Can you see at a glance
whether files are out of
place ? Elimination of
• Can you detect disorder search time
from a distance ?

Before After
2S
COCONUT TO CAR PARKING
BEFORE AFTER

Solutions are available even for complicated things

3 S (Shine everything )
means……

1.Six side cleaning for all.

2. Refurbishing everything
3. Make things easy to clean
3 S (Shine everything )
Six sides of Equipment/Work Place are:

•Top & Bottom side

•Front & Rear side

•Right & Left side

3 S (Shine everything )
Neat & clean Gang ways , painted floor
3 S (Shine everything )
Example of Wet to Dry

Machine lifted above the floor…

… easy to clean from 6 sides
4 S (Standardization)
Benefits
•Sustains the benefits achieved by implementing 1S,
2S & 3S.
•Avoids Re-occurrence.
•Ensures availability of procedures for every activity.
•Ensures continuity of work .
•Provides systematic approach.
•Provides guidelines for the new people.
4 S (Standardization)
Standardization of Colour coding for
Pipe Lines /Containers
Colour Codification Colour Name Description for Application
Green Water
Light Blue Air
Silver Gray Steam
Purple Acids
White Oxygen
Brown Flammable Oils /Liquids

Arrows should be marked to indicate the Direction of Flow. (Colour--- Yellow)

And opening / closing positions of valves
4 S (Standardization)
EXAMPLES OF COLOUR CODING

AIR LINE LIQUIDS/LUBRICATION

LINE
4 S (Standardization)
DIRECT LOADING ON LINE

Method of handling finished parts standardized.

5 S (Self Discipline)
Follow the Standards

“Whatever has been

decided must be
followed exactly as
per the standard”.
5 S (Self Discipline)
Objective
To bring a cultural change in the
organization…...

…….Achieve through

‘Total Employee Involvement’.

5S is not one time activity, it’s a
Continuous IMPROVEMENT
PROCESS .
No TQM,TPM,TPS..LEAN is
possible without 5 S
5S……..a way of life.
 Visual Control
Visual Control: A technique where control of an activity
or process is made easier or more effective by deliberate use
of visual signals.
 They give feedback to an operator about how a process is working
and can alert the operator to act
 Usually used in 5S, but can be implemented with any process
improvement initiative
 Visual Controls can also include audible signals
 The 3 beeps from your microwave once your food has finished
cooking
 Visual Control
The goal of visual controls is to make a process:
 Self-explaining
• Scoreboard at a baseball game
 Self-ordering
• Omnicells
 Self-regulating
• Traffic lights
 Self-improving
• Facilitate corrections in MS Word or email
 Examples of Visual Control
 The red light on your DVR indicating a movie is
recording
 Different colored clothing for different football teams
 Painted lines on the freeway
 The red, yellow and green flags outside of a patient’s
room at a doctor’s office
 Tracking boards in EC driving physician behavior
 Create Visibility through 5 Tatva’s Mapping
Create Visibility through Water ( Liquid) Mapping

Machin Waste in terms of Leak / Excess / over flow /

Liquid used
e/ Not optimized
Area Work
You
Station Chemic You can Chemic
Water Coolant Paint Oil Water Coolant Paint Oil can
No al add al
add
 Create Visibility through 5 Tatva’s Mapping
Create Visibility through EARTH Mapping - Model Line

Other item like Wet area ( Oil /

Machine on See from one
Sr Sectio Material on floor Stands , Racks , water / coolant /
Is floor visible? floor ( Yes / wall to another (
No n ( Yes / No) cupboards fluid / liquid /
No) Yes / No)
directly on floor trash on floor)

HYPE
 Create Visibility through 5 Tatva’s Mapping
Create Visibility through Air Mapping
Machine Compres Air Required Gas used Required Is there Is there
Is there
Are / Work sed air Consump air ? ( If yes , gas any any loss You can You can
any loss
a Station used Yes tion in consumpt type of consumpti Fluid of Fluid add add
of gas ?
No /No CFM ion gas) on used ? ?
 Create Visibility through 5 Tatva’s Mapping
Create Visibility through FIRE Mapping - Model Line
Idle running Excess Excess
Machine Machine Energy Used Energy Used Leakage of
Sr No of Electric consumptio consumption
name No - Power - Gas Energy
motor n of Power of Gas

HYPE
 Create Visibility through 5 Tatva’s Mapping
Create Visibility through Space Mapping - Model Line
Ratio
Value Added space ( of
Non Value added Space ( Area ) Sq. Mtrs
Sq. Mtrs) VA:
NVA
Invent
Mater
Area ory (
ial
Sr in Sq Suppo pallet =
Area Tabl Handl
No Mtrs rt / (Ax10
es Cupboa ing
(C) Machi Operat people Gangwa trolley Empty 0)/C :
Total A and Racks rds and equip Total B
ne ors for y , Space (
Chai similar ment
move storag Bx100
rs storag
ment e of /C)
e
materi
space
al)
 Thanks
Gayathri Lean consultancy
Service offered:
Training & Hands hold implementation support
1. Lean manufacturing techniques
2. TPM (Total productive maintenance)
3. Job method for Assembly operation
4. Micro motion study for Assembly & Robotic operation
5. Dust reduction in painting parts – Robotic and manual spray paint shops

gayathri.leanconsultancy@gmail.com
Contact: 9786257107, 7010378025
Pondicherry –India