1-_workplace_excellence.ppt
- 2. 2 Workplace is – “where one works” “where there is an output” “where there is creative activity” and “where value is being added” What is a Workplace ?
- 3. 3 Workplace is where you do service for the organisation in many forms, such as – Developing a Plan Creating a Strategy Designing a Product Developing a System Producing a product Creating a Document Compiling Data
- 4. 4 Workplace is the reflection of your personality
- 5. 5 Employees can contribute and create quality output much more effectively - Where there is proper organisation Where there is a clean environment. Where there is a serene atmosphere Where the psychological environment is conducive Where the activities are streamlined.
- 6. 6 Surroundings Cleanliness of the place People with whom one works Systems through which we interact Atmosphere – Heat, Light, Ventilation, Dust, Humidity etc. Cultural background of place Ambience – visual and psychological. Physical & Psychological Environment comprise the following -
- 7. 7 Fulfilling Acceptable Satisfying Where one feels needed Where we are seen to be efficient and professional Where we feel proud to work Psychological Environment should be
- 8. 8 5S changes the individual and brings orderliness in him resulting in a clean workplace, clean thinking and removes dirty work habits.
- 9. 9 Why we don’t focus on our workplace ? 1. Lack of Concern for the workplace 2. Don’t give importance to cleanliness and orderliness. 3. Don’t feel the need 4. Don’t bother to keep things Neat & Tidy 5. Cleanliness is not our priority 6. Dirtiness is effortless – Cleanliness needs dedication 7. We don’t stick to Self Discipline 8. We do not take pride in our work 9. We are not proud of our workplace
- 10. 10 What is your workplace like? Before we learn more about 5S, let’s take a look at your workplace first. Which of the following best describes the present condition of your workplace? In my workplace, nobody throws things around. Everybody helps to keep the place clean. In my workplace, people do throw things around but there are cleaners who tidy up the workplace. In my workplace, everybody throws things around and there is nobody to clean the place up
- 11. 11 In my Workplace all necessary items are available in a standardized manner and they can be found with in 30 seconds. In my Workplace necessary items are available but I can not trace the item in 30 seconds. In my Workplace necessary items are not available and I can not trace the items in 30 seconds
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- 13. 13 HOUSE KEEPING A base for any improvement • Even before you plan the direction you • need to take, you must remove any obstacles to get a clear view of the current situation. • House Keeping enhances the results of other activities and simplifies every day operations. • House Keeping must become a habit. It must be continuous, or at least continual activity.
- 14. 14 WHY HOUSE KEEPING LESS EQUIPMENT DOWN TIME. MORE USABLE SPACE. PASSAGE WAYS ARE NEAT AND CLEAN. ABNORMALITIES NOTICED AT A GLANCE. ELIMINATES ACCIDENTS. PRODUCTIVITY IMPROVEMENT.
- 15. 15 WHY HOUSE KEEPING EMPLOYEES FEEL GOOD IF THE WORK PLACE IS CLEAN. SEARCHING IS AVOIDED. TIME WASTED IN HANDLING REDUCED. NO UNNECESSARY SUPPLIES. LESS REJECTION/REWORK. BETTER PREVENTIVE MAINTENANCE.
- 17. 17 DELIVERY SERVICE THE NEED FOR A "5S" STRATEGY
- 18. 18 SIMPLE BUT IMPORTANT CONCEPT A NEAT AND CLEAN FACTORY HAS HIGHER PRODUCTIVITY. A NEAT AND CLEAN FACTORY PRODUCES FEWER DEFECTS. A NEAT AND CLEAN FACTORY MEETS DEADLINES BETTER. A NEAT AND CLEAN FACTORY IS A MUCH SAFER PLACE TO WORK.
- 19. 19 SIMPLE BUT IMPORTANT CONCEPT A NEAT AND CLEAN FACTORY HAS HIGHER PRODUCTIVITY. A NEAT AND CLEAN FACTORY PRODUCES FEWER DEFECTS. A NEAT AND CLEAN FACTORY MEETS DEADLINES BETTER. A NEAT AND CLEAN FACTORY IS A MUCH SAFER PLACE TO WORK.
- 20. 20 THE FUNDAMENTAL TRUTH IF WE CANNOT KEEP OUR WORKPLACES CLEAN ORDERLY ACCIDENT FREE NOBODY WILL BELIEVE WE CAN PRODUCE QUALITY GOODS OR ATLEAST SERIOUS ABOUT PRODUCING QUALITY.
- 21. 21 THE CONCEPT OF "5S" SEIRI - SORTOUT (ORGANIZATION) SEITON - SET IN ORDER (ORDERLINESS) SEISO - SPICK & SPAN (CLEANLINESS) SEIKETSU - STANDARDIZE (CLEAN UP) SHITSUKE - SUSTAIN (DISCIPLINE)
- 22. 22 THE FIRST PILLAR : SORT Sort Means That You Remove All Items From the Workplace That Are Not Needed for Current Production Operation.
- 23. 23 SEIRI - SEGREGATION THIS STEP DISTINGUISHES NECESSARY AND UNNECESSARY ITEMS AND ELIMINATES UNNECESSARY ITEMS. SORT THROUGH AND THEN SORT OUT SORT THROUGH WHAT YOU HAVE. IDENTIFY WHAT YOU NEED AND DISCARD WHAT IS UNNECESSARY INDICATOR OF SUCCESS. AREA OR PERCENTAGE SPACE SAVED.
- 24. 24 1. CLASSIFICATION : SORT OUT. 2. ELIMINATION : REMOVE UNNECESSARY ITEMS. 3. STORAGE : FREQUENT USE/ RARE USE. CLOSE/ DISTANT LOCATION. IDENTIFICATION OF ITEMS & LOCATIONS. 4. FIX & SHARE RESPONSIBILITIES. 5. USE RED TAG SYSTEM. 6. MONITOR PROGRESS.
- 25. 25 WHY SORT IS IMPORTANT?? A WORK ENVIRONMENT IN WHICH TIME MONEY SPACE ENERGY & EFFECTIVE RESOURCES MANAGMENT PROBLEMS IN WORK FLOW ARE REDUCED, COMMUNICATION IS IMPROVED, PRODUCT QUALITY IS INCREASED & PRODUCTIVITY IS ENHANCED.
- 27. 27 THE WASTES IN THE SHOP FLOOR INVENTORY RELATED COSTS TRANSPORTATION QUANTITY HARDER TO SORTOUT DESIGN OBSOLESCENCE QUALITY DEFECTS FROM WIP MACHINE BREAKDOWNS
- 28. 28 SEIRI FACTORY OFFICE HOUSE SCRAPPED MACHINES/ EQUIPMENTS USED/BROKEN PENS BROKEN TOYS REJECTED MATERIALS USELESS PAPERS/FILES OLD CLOTHES EXPIRED GOODS OLD DIARIES BROKEN SUITCASE SCRAPPED/BORKEN TOOLS, PALLETS, BINS, TROLLEYS, ETC BROKEN FURNITURE OLD SHOES EXCESS PARTS OLD NOTICES/ LEAFLETS OLD LETTERS/MAGAZINES UNUSED UTENSILS
- 29. 29 SEIRI FREQUENCY ACTION NOT USED FOR A YEAR OR MORE CONSULT & DECIDE DISPOSAL. SEND TO SOME OTHER PLACE/SELL/SCRAP USED ONLY ONCE IN LAST 6-12 MONTHS STORE AT A DISTANCE / IN RECORDS ROOM USED ONLY ONCE IN LAST 2-6 MONTHS STORE AT A CENTRAL PLACE IN THE WORK AREA USED MORE THAN ONCE A MONTH STORE NEAR WORK PLACE USED WEEKLY / DAILY / HOURLY STORE NEAR WORK PLACE
- 30. 30 THE SECOND PILLAR : SET IN ORDER Set in Order Can Be Defined As Arranging Needed Items So That They Are Easy to Use and Labelling Them So That They Are Easy to Find and Put away.
- 31. 31 SEITON --ARRANGEMENT THIS STEP ENABLES DETERMINATION OF THE TYPE OF STORAGE SYSTEM AND LAYOUT THAT WILL GUARANTEE THAT REQUIRED AMOUNTS OF NECESSARY ITEMS WILL BE EASILY ACCESSIBLE. SET THINGS IN ORDER BY CREATING PLACE FOR EVERYTHING . PUT EVERYTHING IN IT’S PLACE .
- 32. 32 SEITON --ARRANGEMENT USE THE PRINCIPLE OF WIDE RANGE AND SHALLOW DEPTH FOR STORAGE. TIME SAVED IN SEARCHING. TIME SAVED IN HANDLING MATERIAL. KEEPING ACCESSIBILITY AS EASY AS POSSIBLE .
- 33. 33 PROBLEMS AVOIDED BY IMPLEMENTING SET IN ORDER WASTE OF MOTION SEARCHING HUMAN ENERGY EXCESS INVENTORY DEFECTIVE PRODUCTS UNSAFE CONDITIONS
- 34. 34 HOW TO IMPLEMENT SET IN ORDER DECIDING APPROPRIATE LOCATIONS LOCATE ITEMS IN THE WORKPLACE ACCORDING TO THEIR FREQUENCY OF USE PLACE FREQUENTLY USED ITEMS NEAR THE WORKPLACE STORE INFREQUENTLY USED ITEMS AWAY FROM THE PLACE OF USE. A LET GO ARRANGEMENT FOR TOOLS SO THAT THEY GO BACK TO ORIGINAL PLACE OF STORAGE
- 35. 35 HOW TO PROMOTE GOOD ORDER Seldom used, enclose in a separate designated place. THINGS NOT NEEDED: No potential use, immediate disposal after careful analysis. Potentially useful, move to a separate designated place. Require special arrangement disposal.
- 36. 36 THE THIRD PILLAR : SHINE Shine Means Sweeping Floors, Whipping off Machinery, and Generally Making Sure That Everything in the Factory Stays Clean.
- 37. 37 SEISO - CLEANING This step eliminates Dirt, Dust and other foreign matter to make the workplace clean. Clean Equipment,Furniture,Notice Boards Records Etc. Keep the workplace Spotless. Sweeping,wiping,polishing,painting Etc.
- 38. 38 THE FOURTH PILLAR :STANDARDIZE Standardize Is The Result That Exists When the First Three Pillars - Sort, Set in Order and Shine Are Properly Maintained.
- 39. 39 STANDARDIZATION Set in Order Machinery Where Things Are Kept OPERATION Critical Processes Communication Inventory
- 40. 40 SEIKETSU - STANDARDISATION TO ESTABLISH STANDARDS TO MAINTAIN THE IMPROVEMENTS CREATING RULES FOR CHECKING & COUNTERMEASURES. VISUAL CONTROLS FOR STANDARDS AND TO REVEAL ABNORMALITIES TO PREPARE CHECKLISTS AND ADHERE TO AVOID MISTAKES
- 41. 41 SEIKETSU - STANDARDISATION TO ESTABLISH STANDARDS TO MAINTAIN THE IMPROVEMENTS CREATING RULES FOR CHECKING & COUNTERMEASURES. VISUAL CONTROLS FOR STANDARDS AND TO REVEAL ABNORMALITIES TO PREPARE CHECKLISTS AND ADHERE TO AVOID MISTAKES
- 43. 43 HOW TO IMPLEMENT STANDARDIZE VISUAL 5S ANYONE SHOULD DISTINGUISH NORMAL & ABNORMAL CONDITIONS. AT A GLANCE FIVE MINUTE 5S
- 44. 44 HOW TO IMPLEMENT STANDARDIZATION AUDIT THE SHOP FLOOR 5S PROJECTS REVIEW
- 45. 45 THE FIFTH PILLAR : SUSTAIN Sustain means making a habit of properly maintaining correct procedures.
- 46. 46 SHITSUKE - DISCIPLINE THIS STEP IS TO ENSURE THAT EVERYONE STICKS TO THE RULES SCRUPULOUSLY AND MAKES IT A HABIT CREATE GENERAL AWARENESS ABOUT 4S. TRAINING TO EVERYONE. DEVELOP NORMS AND MONITOR SUCCESS.
- 47. 47 SHITSUKE - DISCIPLINE High employee Morale. Involvement of People in the Movement.
- 48. 48 SEIKETSU - TRAINING & DISCIPLINE • EVERY ONE IS STICKING TO THE RULES AND STANDARDS • PRACTISE BY EVERY ONE - MAKES PERFECT • GOOD TRAINING FOR BASIC, HABITUAL MOVEMENTS & ACTIVITIES
- 49. 49 5S IMPLEMENTATION CONTINUING TO LEARN MORE ABOUT THE 5S HELPING TO EDUCATE YOUR CO- WORKERS ABOUT 5S BEING ENTHUSIASTIC ABOUT 5S IMPLEMENTATION. HELPING TO PROMOTE 5S IMPLEMENTATION EFFORTS. 5S TRAINING
- 50. 50 1. THERE CAN BE NO TQM WITHOUT 5 S. 2. A DIRTY FACTORY OR OFFICE CANNOT PRODUCE QUALITY PRODUCTS OR SERVICE. 3. CLUTTER HIDES THE PROBLEM. A NEAT WORKPLACE PROMOTES EASY DISCOVERY OF ABNORMALITIES.
- 51. 51 5S IS THE STARTING POINT FOR ALL WORKPLACE IMPROVEMENTS, PRODUCTIVITY, QUALITY, COST, DELIVERY, SAFETY, SERVICE and MORALE.
- 52. 52 Let us create our own work place with our own hands. Let us contribute to a cleaner work place. 6th. S is now included as “SHIKKARI YAROU” -- “let us try hard”. Every person should show initiative and make a special effort.