Module 4-5S
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The document provides information on implementing the 5S methodology. It includes: 1. An overview of the 5S implementation process which involves sorting, setting in order, shining, standardizing, and self-discipline. 2. Details on the "shine" element which involves adopting cleaning as a daily activity and inspecting defined areas. 3. Examples of ways to prevent dirty floors like using oil collection mats and locating waste oil tanks outside work areas. 4. Actions needed to standardize processes like developing visual controls and assigning responsibilities. 5. The importance of self-discipline which includes recognizing 5S achievements to create good habits.
Module 4-5S
- 1. Draw 5S Plan lay out Explain 5s elements to all staff Select the Task force members 5S Implementation Process 5S Roll Out Step 1: Sorting out carry out workshop Revamp- Major 5S Step 2: Set in order Step 3: Shine Scan the Premises Step 5: Self Discipline Step 4: Standardize
- 2. 5S step 3 implementation Shine (Seiso)
- 3. Adopt cleaning as a daily activity and as a part of inspection. Clean the workplace before starting of the job and before closing the job. Put aside 10 or 15 minutes for the same activity per day. Clean and inspect defined areas, workplace, machines and other items. Cleaning indirectly helps to check or inspect each and every part and place. Hence, it should be a habit. Take remedial action to prevent re-occurrence. Schedule as needed paint coating on buildings, floors, machinery and equipment, during non productive times SEISO (SHINE)
- 4. Find ways to prevent dirt and contamination. Sweeping checklists are applied throughout the day for each of the common areas Safety inspections are performed on a regularly scheduled basis Workers should be responsible to clean the machines, tools, work benches in their individual workplace. Sweepers should be responsible for the common areas outside and inside the premises
- 5. Oily floors are a common problem created by: Oil leaking from engines, transmissions and brake systems and spoiling the floor Keeping the transmission and other parts on the floor, spilling the oil. Draining the oil into a pan, spilling it on the floor. Carrying the oil pan to a waste oil drum and carelessly emptying it in the drum. Note the condition of floor in the photograph. Use 5 Whys or cause-and-effect methods to find the root causes of slippery floor and take appropriate corrective and preventive action.
- 6. WHY 1 Used Engine oil is Emptied in a drum manually causing it to spill on the floor Ask "WHY" five times - get to the root cause of why the working bays get dirty Proper oil collector is not used for draining the oil. WHY 2 While carrying it to the drum, oil spills all over the place. WHY 3 The oil drum is located at a long distance WHY 4 Manual transportation of the used engine oil is the main cause of oil Spilling on the floors WHY 5 Root cause Conclusion: The used oil should not be transported manually to the waste oil drum
- 7. Air line to oil drain trolley pump Oil drain trolley with evacuation pump A B c Method of preventing oil spillage on the ground Waste oil tank located outside the working area(hidden from view) PVC /FRP WASTE OIL TANK Waste oil sucked by the purchaser’s tanker Making use of the root cause analysis, the task force came up with the above solution to prevent oil spillage.
- 8. Floor rubber mats can be laid under the car lift to prevent leaking engine and transmission oils spoiling the floor. There is no special rubber quality required, local grades of thick rubber sheets would be ok. The rubber sheet can be washed with a chemical or detergent frequently.
- 9. 5S Step 4 implementation SEIKETSU(STANDARDIZE)
- 10. Wake up Sleeping Beauty !!!!
- 11. SEIKETSU (Standardize) •Establish standards. Develop visual controls to expose abnormality. •integrate with daily work management. •Prevent deterioration using 5W & 1H strategy. Standards improve reliability and consistency.
- 12. Actions items 1. Take “before” photographs.(See module 2 for before photos) 2. Check that the first three S’s are implemented properly. 3. All team activity documents/check lists should be publicly displayed on a 5S board. 4. Establish the routines and standard practices for regularly and systematically repeating the first three S’s. 5. Create procedures and forms for regularly evaluating the status of the first three S’s. 6. Standardize red tag procedures and holding area rules (see Seiri).
- 13. 7. Standardize procedures for creating shadow boards, position lines, and labeling of all items (see Seiton). 8. Standardize cleaning schedules using the “5S Owner Check Sheets” (see Seiso). 9. Standardize “single-point lessons” for documenting and communicating 5S procedures and improvements in workplace and equipment. 10. Create a maintenance system for housekeeping. Make a schedule for cleaning of the workplace. A common approach is to ask a cross-functional team to do it. 11. Inter-departmental competition is an effective means of sustaining and enhancing interest in 5S. 12. Assign responsibility to individuals for a work area and machinery.
- 14. Check out Kaizen suggestion form.xlsx 13. Regular inspection/audit and evaluation by a special team (including senior management persons) to be continued. 14. Instead of criticizing poor cases, praise and commend good practices or good performers. 15. Take “after” photographs and post them on the 5S board(s). 16. Complete evaluation using 5S levels of implementation with the facility manager or the authorized persons in the organization
- 16. •Create an environment through slogans, posters and other visuals •Set an example, from a habit. •Conduct audits to evaluate approach and results. Recognize 5S achievements 5. SHITSUKE (SELF DISCIPLINE) Action speaks louder than the words March04 audit.xls
- 17. Fix up a day when your workshop staff takes a break from the usual boring schedule. Announce at least 3 winners who have scored maximum points in the 5S audit. Distribute T shirts or badges to winners.