Taklimat
Pelaksanaan
Aktiviti Amalan
5S
ADTEC Taiping
21-22 Jun 2010
Oleh:
Junnaina Binti Husin Chua
Muzafar Shah Bin Mohd Shah
JAPANESE
ENGLISH
BAHASA
MELAYU
SEIRI
SORT
SISIH
SEITON
SET IN ORDER
SUSUN
SEISOU
SHINE
SAPU
SEIKETSU
STANDARDISE
SERAGAM
SHITSUKE
SUSTAINE
SENTIASA
AMAL
ERTI
PEMBENTUKAN
(ORGANISATION)
KEKEMASAN
(NEATNESS)
BERSIHKAN
(CLEANING)
PIAWAIAN
(STANDARDISATION)
DISIPLIN
(DISCIPLINE)
CONTOH
Buang sampah sarap
Mendapatkan dokumen
dalam masa 30 saat
Setiap orang bersihkan
tempat kerjanya sendiri
Tempat penyimpanan
yang jelas dan mudah
digunakan
Lakukan 5S setiap hari
QUALITY
EMPLOYABILITY
WHERE?
TOOLS
INDIVIDUAL
1. MS ISO
WORKSHOPS
2. KAIZEN
WORKPLACE
3. TQM
QUALITY
EMPLOYABILITY
5S ACTIVITIES
MAIN
OPERATIONS
IMPROVEMENT
1. Working Habits
PROBLEM
2.
3.
FACILITIES
Monitoring
Control
TRAINING
MATERIALS
SUPPLY

Waste Reduction (Generation, Disposal)

Gain Control

Improvement (Innovation, Kaizen)

Standardize (maintenance, critical parameters,
procedures)
(equipment, material & Inventories)
Wasteful, no add value, unproductive
unevenness
overburden
T
I
M
W
O
O
D
S
: Transportation
: Inventory
: Motion
: Wait
: Over-processing
: Over-production
: Defect
: Searching
5S
Systematic
Organization
WASTE /
IMPROVEMENT
Reduce Finding Time
Reduce Selection Error
Reduce Finding Time
Sorting Visual Reduce Errors
Placement
Reduce unnecessary
movement
Reduce downtime
Scrubbing
Reduce repairing time
Clean
Increase equipment
knowledge
BENEFITS
Cost Reduction
Improve Quality
Faster
Increase Productivity
Increase Safety &
Quality
More Space
Increase Safety
Increase Uptime
STEERING
COMMITTEE
Policy Maker
May ~ July
2009
SECRETARIATE
July 2009
5S TEAM
Facilitator
Leader
Implementer
SUPPORTING TEAM
Members
Audit
Promotion
Improvement
Training
Jan 2010
STAGES DEPTs
PILOT
TEAM
1st
G
2nd G
UNITs
ADMIN
8 ppl
8 ppl
4 ppl
(HOD + Rep) X
4 Depts
(PP + Rep) X 4
Units
1 PPT (PA)
3 PAP
1 SGA X 4
1 SGA X 4
Dept
Units
3 SGAs X 4
1 SGA X 4
Dept
Units
1 SGA
3 SGAs
(Pent, Kew, &
Asrama)
JPA
1 Rep
1 SGA
1 SGA

Team  Bhg. Tek. Mekatronik

Location  Workshop 1

Schedule
ACTIVITY
NO. of DAYS
SCHEDULE
Check List Preparation
2
9~10 Feb
Floor Plan
5
11~19 Feb
Material Identification
4
22~25 Feb
Work Determination
5
1~5 Mac
Preliminary
1)
2)
3)
4)
5)
6)
Preliminary
Seiri
Seiton
Seisou
Seiketsu
Shitsuke

Target Area
 Define Workplace
 Layout/floor plan

Purpose and Functions
 Main Activities
 Key persons
 Materials required

Evidences
 Photos
 Data
 Target (objectives)

Display Board
1. Separate items by categories
a) Stock
b) Facilities
c) Location
d) Documents
e) Machines
f) Fittings
g) Stationeries
h) Others
2. Do it with colleague, look for
a) Wanted vs. Unwanted
b) Needed vs. Not Needed
c) Doubt  move it out
3. Perform Visual Control
a) Policies  Steering Committee
b) Categories  easy to relocate

Is this item needed?

Tagging
 Unneeded
 Needed
 Unknown usage
▪ in what quantity?
▪ how frequent it been used?
▪ Where should it be
located?
 Unwanted
 Excessive
 Defective items
 Dead Stock
 Not needed
 Sleeping Stock
▪ How should it be disposed?
▪ Where to disposed? (Holding
 Leftovers Materials
area –Gemba, Dept, Institute)
▪ When to disposed?

Evaluation
Seiri audit checklist
S1: Seiri=Sort (Clear up)
1. Are there any tools, spare parts, materials left on the floor, nearby
equipment?
2. Are all frequently used objects sorted, arranged, stored and labeled?
3. Are all measurement instruments/devices sorted, arranged, stored and
labeled?
4. Does the inventory or in-process inventory include any unneeded materials
or parts?
5. Are there any unused machines or other equipment around?
6. Are there any unused jigs, tools, dies or similar items around?
7. Is it obvious which items have been marked as unnecessary?
8. Has establishing the 5S’s left behind any useless standards?
Rate

Visual Layout
 Look around with colleague
 Decide the most effective working flow
by frequency
▪ Hourly/Daily
▪ Weekly
▪ Monthly/Yearly

Labeling
 Divide the workplace into sections
▪ Frequency of usage
▪
▪
▪
▪
Hourly
Daily
Weekly
Monthly
▪ Type of item
▪ In use
▪ Stock

Layout
 Draw workplace layout
▪ Machine’s location
▪ PIC
▪ Pictures

4W1H

30 sec detection

Inform everyone

Lines




Equipment
Supplies
Common Areas
Safety Zones

Lines (cont’)
 Divider
 Outlines
 Arrow  Direction, rotation
 Limit (max/min  height, weight, qty)

Label
 Colour Coding
 Item Location
 Signs
Equipment related information (SOP)
Showing location, type, qty

PLAN







Root Cause
Improvement
Kaizen
DO

What to clean
Who in-charge
Cleaning method
ACTION




Cleaning Schedule
Cleaning Tools
CHECK

Reoccurrence
(dirt/dust)
Cleaning
 Major Cleaning Day (overall)
 Daily Routine
(10-15 mins)
 Weekly/Monthly (specific area)

Checking (4W1H + cause n effect)
 Prevent reoccurrence
 Preventive Maintenance
Cleaning Schedule
Owner Log
Improvement (Progress chart)
Plan
Activities chart
Responsibilities

Establish guideline (team, visual)

Develop standards

Objective
Team maintain adherence to the standard
How?
5S Training
Communication Board
Evidence
Visual Standard and procedures
Daily 5 min activities
Weekly 5S application