3C & 5S.ppt
- 1. NATHAN & NATHAN CONSULTANTS PVT LTD 1 PROCANDOUR AUTOMOTIVE SYSTEM PRIVATE LIMITED WELCOMES THE PARTICIPANTS FOR WORKSHOP ON 5S PRACTICES
- 2. NATHAN & NATHAN CONSULTANTS PVT LTD 2 INTRODUCTION • NEED FOR 5S • HOUSEKEEPING LEVELS • BENEFITS OF 5S PRACTICES • BASIC CONCEPTS OF 5S • BENEFITS
- 3. NATHAN & NATHAN CONSULTANTS PVT LTD 3 What is 5S ? • An essential step required for Waste Elimination • An integral step in Kaizen • A required element to achieve Lean-site Manufacturing Standardization/Perseverance “Shitsuke” Systematic Organization “Seiri” Orderliness “Seiton” Cleanliness “Seiso” Cleanup “Seiketsu”
- 4. NATHAN & NATHAN CONSULTANTS PVT LTD 4 WHY ‘5S’? • Helps in TPM Implementation • Reducing M/C Downtime • Safety • Establishes an Ambience for Quality • Creates a Healthier Corporate Climate • Better Operational Control of Process • It is a Scientific Method for Good Housekeeping
- 5. NATHAN & NATHAN CONSULTANTS PVT LTD 5 HOUSEKEEPING Housekeeping is a process wherein everyone in the company is committed to and involved in up keeping of the workplace and cleanliness of m/c, material etc., such that only needed material is kept and it’s fastest accessibility is ensured
- 6. NATHAN & NATHAN CONSULTANTS PVT LTD 6 5 LEVELS OF HOUSEKEEPING • Level 1: - Floor is full of unwanted material • Level 2: - Clutter found by the walls • Level 3: - Factory / office is clean but tools, papers, files & material disorganized • Level 4: - Storage area, m/c, offices are clean & furniture, documents and material organized • Level 5: - Factory / office is immaculate
- 7. NATHAN & NATHAN CONSULTANTS PVT LTD 7 5 PILLARS OF VISUAL WORKPLACE ‘5S’s are the five keys to Total Quality Environment. These are: SEIRI - Sorting Out SEITON - Arrangement (Systematic) SEISO - Spic and Span (Cleanliness) SEIKETSU - Standardization (Neatness) SHITSUKE - Discipline (-Self)
- 8. NATHAN & NATHAN CONSULTANTS PVT LTD 8 RESISTANCE TO IMPLEMENTING THE 5 PILLARS • What is so great about Organisation & Orderliness. (O&O) • Why clean when it just gets dirty. • Implementing O&O will not boost output. • We have already implemented O&O. • We did the 5 Pillars years ago. • We are too busy to spend TIME ON O&O. • Why do we need to implement 5 Pillars?
- 9. NATHAN & NATHAN CONSULTANTS PVT LTD 9 BENEFITS OF IMPLEMENTING 5 PILLARS INDIVIDUAL & COMPANY
- 10. NATHAN & NATHAN CONSULTANTS PVT LTD 10 BENEFITS TO INDIVIDUAL •Pleasant and Clean workplace •Make your job more satisfying •Remove many obstacles and frustration in your work •Help you to know your work and also when and where to do it •Makes it easy to communicate •Kindle your Creative Thinking
- 11. NATHAN & NATHAN CONSULTANTS PVT LTD 11 BENEFITS TO ORGANISATION •Increasing Product Diversity •Improving Quality •Decreasing Cost •Providing Timely Deliveries •Promoting Safety •Building customer Confidence •Providing Corporate Growth
- 12. NATHAN & NATHAN CONSULTANTS PVT LTD 12 SEVEN WASTES WASTE FROM –OVERPRODUCTION –WAITING TIME –TRANSPORTATION –PROCESS –INVENTORY –UNWANTED MOTION –PRODUCTION DEFECTS
- 13. NATHAN & NATHAN CONSULTANTS PVT LTD 13 NEAT AND CLEAN FACTORY HAS •HIGHER PRODUCTIVITY •LESSER DEFECTS •BETTER DELIVERIES •IMPROVED SAFETY •HIGH MORALE •LOWER COST
- 14. NATHAN & NATHAN CONSULTANTS PVT LTD 14 SEIRI (Sorting Out) Meaning:Putting things in order, Sorting, Removing what is not needed and keeping what is needed. Activities: Sort through and then sort out Sort through what you have, Identify which are all required, Discard what is unnecessary & Dealing with the causes of filth. House Cleaning
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- 17. NATHAN & NATHAN CONSULTANTS PVT LTD 17 SEIRI : Guidelines • Things we don’t use: discard. • Things We don’t use but want to have on hand just-in-case: • Keep as contingency items. • Things we use only infrequently: store somewhere far away • Things we use sometimes: store in workplace • Things we use frequently: keep at workplace or on the person
- 18. NATHAN & NATHAN CONSULTANTS PVT LTD 18 PROBLEMS FACED When Workplace is not organised properly the following problems arise- • Shop-floor more crowded and hard to work in • Storage cupboards and lockers between machines create walls thereby affecting communication • Time lost while searching for parts, tools etc. • Excess inventory of parts, tools and machine result in increased cost. • Stock in hand hides other types of problems in production • Unwanted items in shop-floor make it harder to improve the process flow.
- 19. NATHAN & NATHAN CONSULTANTS PVT LTD 19 IMPLEMENTING FIRST ‘S’ RED TAG STRATEGY •Red Tag is put on all items to be identified •When identified, evaluate and decide •Decisions could be •Hold in Red Tag Holding Area for sometime to decide whether they are needed or not •Disposed •Relocated •Left in the shop where they are
- 20. NATHAN & NATHAN CONSULTANTS PVT LTD 20 STEPS IN RED TAGGING •Launch Red Tag Project •Identify Red Tag targets •Set Red Tag criteria •Make Red Tags •Attach Red Tags •Evaluate Red Tagged items •Document the results of Red Tagging
- 21. NATHAN & NATHAN CONSULTANTS PVT LTD 21 RED TAG TARGETS • EQUIPMENT – Machines – Equipments – Jigs and Tools – Cutting Tools – Gauges – Carts and handling – Worktable – Cabinets, desks, chairs • PHYSICAL AREAS – Production area – Walkways – Walls,shelves – Warehouses • INVENTORY – Raw material – In Process – Sub Assembly – Semi Finished – Finished
- 22. NATHAN & NATHAN CONSULTANTS PVT LTD 22 DISPOSAL METHODS •Throw away - as scrap or incinerate •Sell •Return to source •Lend to other departments-Temporary basis •Distribute to other Units-permanent •Central Red Tag area for decision
- 23. NATHAN & NATHAN CONSULTANTS PVT LTD 23 TYPES OF UNWANTED ITEMS •Defective or excess parts •Obsolete or broken Jig, tools & gauges •Worn out tools •Old rags and cleaning supplies •Unsafe or broken electrical units •Outdated poster, signs,notices & memos
- 24. NATHAN & NATHAN CONSULTANTS PVT LTD 24 PLACES WHERE UNWANTED ITEMS ACCUMULATE • No man’s Land • Corners near entrance and exit • Along interior & exterior walls, next to partitions & behind pillars • Under the eaves of warehouses • Under desk, shelves and cabinets • Unused exhibit boards • In Tool Boxes which are not clearly sorted
- 25. NATHAN & NATHAN CONSULTANTS PVT LTD 25 ‘SEITON’: Systematic Arrangement Meaning: Keep things in such a manner that people can reach them easily whenever they need. – Design/plan Functional Storage based upon 5W1H – Create place for everything & everything in it’s place – Keep accessibility as easy as possible, also minimum material handling – Zoning and placement marks – First In First Out (FIFO)
- 26. NATHAN & NATHAN CONSULTANTS PVT LTD 26 IMPLEMENTING ORDERLINESS - DECIDING APPROPRIATE LOCATIONS. – PRINCIPLES OF STORING JIGS,TOOLS & DIES – PRINCIPLES OF MOTION ECONOMY. – 5S MAP. – IDENTIFYING LOCATIONS – SIGN BOARD STRATEGY. – PAINTING STRATEGY. – COLOUR CODING STRATEGY. – OUTLINING STRATEGY.
- 27. NATHAN & NATHAN CONSULTANTS PVT LTD 27 PRINCIPLES OF STORING JIGS, TOOLS & DIES • FREQUENCY OF USE. • SEQUENCE OF USE. • EASE OF HANDLING. • VARIETY ELIMINATION OF JIGS & DIES. • STORE TOOLS BY PRODUCT.
- 28. NATHAN & NATHAN CONSULTANTS PVT LTD 28 PRINCIPLES OF MOTION ECONOMY • START AND END EACH MOTION WITH BOTH HANDS MOVING AT ONCE. • USE GRAVITY INSTEAD OF MUSCLE • AVOID ZIGZAG AND CHANGE IN DIRECTION • USE FOOT OPERATED SWITCHES • KEEP MATERIAL AND TOOLS IN FRONT AND IN ORDER OF USE • OPERATOR AT PROPER HEIGHT • POSITION PARTS AND MATERIAL FOR EASY REACH • PROPER HANDLES AND GRIPS
- 29. NATHAN & NATHAN CONSULTANTS PVT LTD 29 SEISO: (SPIC & SPAN) Meaning: Keeping things clean and polished, no trash or dirt anywhere in the workplace. Activities: • Clean equipment, tools, furniture, notice boards, records etc. • Keep the workplace spotlessly clean. • Locating (inspection) and attending to minor problems while cleaning. • Sweeping, wiping, polishing, painting etc. • Everybody acting like a caretaker. • Clean even places most people do not notice
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- 32. NATHAN & NATHAN CONSULTANTS PVT LTD 32 SEISO: The Three Approach • MACRO • INDIVIDUAL • MICRO Cleaning everything and dealing with the overall causes Cleaning specific work places and specific piece of machinery Cleaning specific parts and tools and the causes of grime are identified and corrected
- 33. NATHAN & NATHAN CONSULTANTS PVT LTD 33 IMPLEMENTING CLEANLINESS • DETERMINE CLEANLINESS TARGETS • WAREHOUSE ITEMS • EQUIPMENT • SPACE • DETERMINE CLEANLINESS ASSIGNMENTS • 5S ASSIGNMENT MAP • 5S SCHEDULE • DETERMINE CLEANLINESS METHODS • DECIDE CLEANLINESS TARGETS & TOOLS • STANDARDS FOR CLEANLINESS PROCEDURES • IMPLEMENT CLEANLINESS
- 34. NATHAN & NATHAN CONSULTANTS PVT LTD 34 TYPES OF EQUIPMENT PROBLEM • OIL LEAKS • DIRTY - OPERATOR RELUCTANT • GAUGES AND INDICATORS NOT ACCESSIBLE AND NOT EASY TO READ • NUTS & BOOLTS MISSING OR LOOSE • MOTORS OVERHEAT • SPARKS FLARE FROM POWER CORDS • V BELTS LOOSE OR BROKEN • STRANGE NOISE
- 35. NATHAN & NATHAN CONSULTANTS PVT LTD 35 STEPS IN CLEANLINESS INSPECTION • DETERMINE CLEANLINESS TARGETS • MACHINES & EQUIPMENTS • JIGS, TOOLS & DIES,GAUGES • ASSIGN CLEANLINESS INSPECTION JOBS • MAINLY WORKERS, SUPERVISORS & GROUP LEADERS • LARGE SIGNBOARD FOR SHOP & SMALL FOR EACH M/C • DECIDE CLEANLINESS INSPECTION CHECKLISTS • IMPLEMENT CLEANLINESS INSPECTION
- 36. NATHAN & NATHAN CONSULTANTS PVT LTD 36 SEIKETSU: (STANDARDIZATION) Meaning: Maintaining cleanliness, after cleaning eliminating germs and stains; also standardization. Activities: • Establish management standards for maintaining the 5Ss • Introduce innovative visible management • Color coded pipes, warning colors, inspection marks • Early detection and early action • Okay marks, Marking on meters • Belt size labels • Fire extinguisher signs
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- 38. NATHAN & NATHAN CONSULTANTS PVT LTD 38 CONTINUOUS EFFECTIVE STANDARDISED CLEANUP • BY TAKING TO NEXT LEVEL OF PREVENTION USING 5W1H APPROACH • PREVENTIVE ORGANISATION • PREVENTIVE ORDERLINESS • PREVENTIVE CLEANLINESS
- 39. NATHAN & NATHAN CONSULTANTS PVT LTD 39 SHITSUKE: (SELF-DISCIPLINE) Meaning: Inspiring pride in the workplace and scrupulous adherence to standards in the other four components Activities: • Create good awareness about 5S – Training to everyone • Develop norms: e.g.., one minute 5S, Exercise time, Group cleaning • Preparation of 5S manuals • Communication and feedback • Individual responsibility and total employee involvement • Practicing good habits • Regular monitoring through audits • Seeing is believing
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- 41. NATHAN & NATHAN CONSULTANTS PVT LTD 41 IMPLEMENTING DISCIPLINE • AWARENESS OF 5 PILLARS & DISCIPLINE TO IMPLEMENTATION • ALLOCATE ENOUGH TIME IN WORK SCHEDULE FOR 5 PILLAR IMPLEMENTATION • STRUCTURE TO IMPLEMENT 5 PILLARS • SUPPORT FROM MANAGEMENT BY WAY OF ACKNOWLEDGEMENT, LEADERSHIPAND RESOURCES • REWARDS AND RECOGNITIONS • SATISFACTION & EXCITEMENT
- 42. NATHAN & NATHAN CONSULTANTS PVT LTD 42 TOOLS & TECHNIQUES FOR PROMOTING DISCIPLINE • 5S SLOGANS • 5S POSTERS • 5S PHOTO EXHIBITION • 5S NEWSLETTERS • 5S MAPS • 5S POCKET MANUALS • 5S MONTHS
- 43. NATHAN & NATHAN CONSULTANTS PVT LTD 43 MANAGEMENT ROLE • EDUCATING EVERYONE ON 5S CONCEPTS, TOOLS & TECHNIQUE • CREATING TEAMS FOR 5S IMPLEMENTATION • ALLOWING TIME FOR IMPLEMENTATION & CREAT SCHEDULES • PROVIDE RESOURCES • ACKNOWLEDGE AND SUPPORT 5S EFFORTS • ENCOURAGE CREATIVE INVOLVEMENT BY ALLWORKERS, LISTENING TO THEM & ACTING ON THEM • PROMOTING TANGIBLE & INTANGIBLE REWARDS • CONTINUOUS PROMOTION OF 5S EFFORTS (ONGOING)
- 44. NATHAN & NATHAN CONSULTANTS PVT LTD 44 ROLE OF SUPERVISORS & WORKMEN • SUPERVISORS & MANAGERS • IMPROVING QUALITY & EFFICIENCY OF THEIR OWN WORK • TEACHING BY EXAMPLE • DEMONSTRATING COMPANY’S COMMITMENT • WORKMEN • CONTINUE TO LEARN MORE ON 5S IMPLEMENTATION • EDUCATE COWORKERS • TAKE INITIATIVE TO IMPLEMENT 5S ON DAILY BASIS • GENERATE CREATIVE IDEAS & INFORM • 100% EFFORTS IN IMPLEMENTATION
- 45. NATHAN & NATHAN CONSULTANTS PVT LTD 45 BEFORE AND AFTER - 5S 5 S Element Waste/ Improvement Item Deliverable Systematic Organization Elimination of finding. Reduction of part selection errors. Reduced Costs Improved Quality Increased Product Options Sorting-Visual Placement Elimination of finding. Elimination of nonconformances. Elimination of motion. Reduction of part selection errors. Reduced Costs Increased Safety Improved Quality Increased Product Options. Scrubbing Clean Increased safety. Preventive maintenance. Increased equipment knowledge. Increased Safety Improved Quality Standardization Control Increased equipment life. Higher morale. Clean environment. Increased visibility of nonconformances. Improved Quality Consistent Delivery Improved Safety
- 46. NATHAN & NATHAN CONSULTANTS PVT LTD 46 BEFORE AND AFTER - 5S
- 47. NATHAN & NATHAN CONSULTANTS PVT LTD 47 BEFORE AND AFTER - 5S
- 48. NATHAN & NATHAN CONSULTANTS PVT LTD 48 BEFORE AND AFTER - 5S
- 49. NATHAN & NATHAN CONSULTANTS PVT LTD 49 BEFORE AND AFTER - 5S
- 50. NATHAN & NATHAN CONSULTANTS PVT LTD 50 BEFORE AND AFTER - 5S
- 51. NATHAN & NATHAN CONSULTANTS PVT LTD 51 ARE WE READY TO CHANGE OUR TOTAL QUALITY ENVIRONMENT
- 52. NATHAN & NATHAN CONSULTANTS PVT LTD 52 WITHOUT YOUR ACTION A TERRIBLE THING WILL HAPPEN ?
- 53. NATHAN & NATHAN CONSULTANTS PVT LTD 53 THANK YOU FOR YOUR PRECIOUS TIME!!
- 54. NATHAN & NATHAN CONSULTANTS PVT LTD 54 NOTHING!!