Quality Improvements
INDIA
1950
1960
1970
1980
1
1. 5S Principles
 Elimination of waste
 Every body is involved, Cooperative effort
 Attack root cause
 Human being is not infalliable
2
2. Objectives
 Improve housekeeping
 Make every individual
responsible for housekeeping
 Beautify by simple means
 Productivity improvement by
saving time, space etc.
3
3. 5S’s
• Seiri
• Seiton
• Seiso
- Sorting
- Systematic arrangement
- Cleaning
Inspection while cleaning
• Seiketsu - Standardization
• Shitsuke - Self Discipline
4
5S
If we do not do 5S, we can’t do any
other work efficiently. They are
features which are common to all
places and are the indicators of
how well an organization is
functioning.
5
SEIRI = Sorting
Meaning
Distinguish between necessary and unnecessary
items and eliminate the unnecessary items
Activity
Establish a criteria for eliminating unwanted items
Eliminate unwanted items either by disposing
them or by relocating them.
Success
Indicator
Area saved or percentage of space available
6
SEIRI = Sorting
Japanese Meaning :
The Japanese
meaning of “Seiri” is to straighten and
contain.
- Get rid of waste and put it in order according
to rules
OTHER JAPANESE MEANINGS farmland cultivation, Make an orderly system
and straighten
7
Seiri = Sorting
What is unnecessary
1. Item is not needed
2. Item is needed however quantity in stock is more
than what is needed for consumption in near
future
3. Contingency Parts
Critically decide the quantity of contingency
parts to be retained and criteria for such parts
8
Organization
Frequency of use
LOW
Storage Method
*Things you have not used Throw them out
in the past one year
*Things you have used once Store at distance OR
in the last 6-12 months
Keep in store
*Things you have used only Store it in central place
once in the last 2-6 months in your zone
*Things used more than once Store it in central place
a month
in your zone
HIGH
*Things used once a week
Store near the workplace
*Things used daily or hourly Store near the workplace
9
Seiri = Sorting
Identifying unnecessary
1. Parts & Work in Process (WIP)
• Things fallen back behind the machine or rolled under it
• Broken items inside the machine
• Things under the racks/ platform
• Extra WIP
• Stock of rejected items
• Items accumulated over period for rework
• Material awaiting disposal decision
• Material brought for some trial, still lying even after trial
• Small qty of material no longer in use
Contd..
10
Seiri = Sorting
Identifying unnecessary
2. Tools, Toolings, Measuring devices
• Old jigs, tools not in use are lying
• Modified tools, tooling for trial, are lying after trial
• Worn out items like bushes, liners, toggles etc. lying
• Broken tools, bits, etc. may be lying
• Measuring equipment not required for the operation
being performed , is lying
3. Contingency Parts
• Many times storage place for contingency parts become
a last refuge for broken parts, surplus items and things
nobody is likely to use
Contd..
11
Seiri = Sorting
Identifying unnecessary
4. Shelves and Lockers
• Shelves and lockers tends to collect things that nobody
ever uses , like surplus, broken items etc.
5. Passages and Corners
• Dust, material not required seem to gather in corner
6. Besides Pillars and under the stairs
• These places tends to collect junk, spittoon etc.
7. Walls and Bulletin Boards
• Old out dated notices which have lost their relevance
• Posters or bulletins on wall
• Dust, remains of torn notices, cell tape pieces
Contd..
12
Seiri = Sorting
Identifying unnecessary
8.Floor, Pits, Partitions
• Defective parts
• Protection caps, covers
• Packing material
• Hardware items , small items
• Even tools, tooling
Items dropped on the floor are never picked
9.Computer Hard Disk
• Many unwanted, outdated, temporary files pile up
13
Seiri = Sorting
Improvement methods
1. Flow Process Chart (Procedural Analysis)
Drawing a process flow chart for the system
eg. How to make and use category wise grouping
2. Operational Analysis
Preparing the sequence of operations for system
eg. How to perform Seiri (sorting)
3. Check List
A check sheet is used to decide what sort of main system
and sub system are necessary.
14
Seiri = Sorting
Dealing with papers
How to reduce papers on
your table ?
1. Make a single pile of papers
2. Go through them and sort in
following categories
a) Immediate action
b) Low priority
c) Pending
d) Reading material
e) For information
15
Seiri = Sorting
Dealing with papers
How to reduce papers on
your table ?
4 D Principle
DO
DELEGATE
DELAY
DUMP
16
SEITION = Systematic Arrangement
Meaning
Activity
To determine type of storage and layout that
will ensure easy accessibility for everyone .
- Functional storage
- Creating place for everything and putting
everything in its place
Success - Time saved in searching
Indicator - Time saved in material handling
17
SEITION = Systematic Arrangement
Japanese Meaning:
Dictionary meaning of Seiton is “to be correctly
prepared”and “to prepare correctly”.
In short these means :
(a) arrange correctly in accordance with the correct method of
doing activities and
(b) make thorough preparations so that activities can be done
even if they occur abruptly
18
SEITION = Systematic Arrangement
The main target areas for Seri-Seiton improvement are :
Tool-setting and preparation operations, line balancing and
process planning, parts supply to assembly line, peak time
problems etc.
Improvement Methods
Kit Method / Assembly box method / Outside tool setting
Cassettisation / Parallel operations / Changes in assignment
method
19
Seiton = Systematic Arrangement
How to achieve Systematic Arrangement ?
• Decide where things belong
• Decide how things should be put away
• Obey the Put away rules
20
Seiton = Systematic Arrangement
How to achieve Systematic Arrangement ?
• Decide where things belong
- Standardize Nomenclature
- Determine an analytical method of storage
• Decide how things should be put away
- Name & locations to everything. Label both item
and location
- Store material functionally
- Prevent mistakes with coding by shapes & colour
contd..
21
Seiton = Systematic Arrangement
How to achieve Systematic Arrangement ?
• Decide how things should be put away
- Follow first in first out rule
- If two identical items are to be located, then store
them separately, colour code them.
• Obey the rules
- Put the things back to their location after
their use
22
Seiton = Systematic Arrangement
USE :
1 ) Signboards
2) Colour codes
3) Outline markings
4) Labels
23
Seiton = Systematic Arrangement
Functional
Storage
24
Seiton = Systematic Arrangement
Usage
• Store frequently used material
Frequency near the workplace and less
frequently at some distance
Weight &
Shape of the
Material
• Heavy material should be stored
at lower levels/layers
Place directly on the material
handling device for ease of
handling
Functional Storage
25
Seiton = Systematic Arrangement
Category
Operation
Wise
• Same category of material may be
stored in one location.
Eg. Allen Screws, Oil Seals
• All items required for an
operation may be stored in one
location.
Eg. Allen key, spanner etc hand
tools required for setting m/c
Functional Storage
26
Seiton = Systematic Arrangement
• Outlining and Placement Marks
- Mark boundaries of dept., aisles, Machines
- Follow straight line, right angle rule
- Nothing shall be kept outside the boundaries
• Stands and shelves
- Keep only required number of stands and shelves
- Standardize height, size
- Provide casters where necessary so that it can be
moved
27
Seiton = Systematic Arrangement
• Wires and Ducts
- Colour code
- When there are multiple connections - bundle the
wires, label them and make sure that they are in
straight line /right angle and firmly anchored
• Machine-tools & Tools
- Put the tools in the order you need them
- Location of the tool should be such that it can be
put away with one hand
- Try to eliminate some hand tools by permanently
attaching it to the bolt head
28
Seiton = Systematic Arrangement
• Blades, Dies, Other important consumables
- Store them in the protected place
- Maintain these things regularly by applying rust
preventive, oiling etc.
• WIP- Work In Process
- Designate a place for each component/part
- Decide on how much quantity to be stored
- Ensure that there is no damage to good part
during transit, they do not get rusty and they are
not mislabeled
29
Seiton = Systematic Arrangement
• Oils
- Reduce number of oils used (Standardize)
- Colour code for oil
- Safety aspects - fire prevention, pollution, leak,
spillage
• Instrumentation & Measuring Devices
- Label them, show direction of flow
30
SEISO = Cleaning
Meaning
Cleaning trash, filth, dust and other foreign
matter. Cleaning as a form of Inspection
Activity
- Keep workplace spotlessly clean
- Inspection while cleaning
- Finding minor problems with cleaning inspection
Success
Indicator
- Reduction in machine down time
- Reduction in no. of accidents
31
SEISO = Cleaning
Japanese Meaning :
Dictionary meaning “to clean up” and
“getting rid of dirt and unclean items”
While cleaning potential defects such as
abrasion, damage, loose parts,
deformities, leaks temp., vibration,
abnormal sound etc. are revealed hence
Seiso is Inspection
32
Seiso = Cleaning
• Here cleaning means more than just keeping
things clean. Cleaning should be viewed as a
form of Visual Inspection
• Preventive measures should be taken to tackle
problems of dust, grim, burrs, leakage etc.
Root cause of the problem should be identified
and it should be eliminated
33
Seiso = Cleaning
Various Minor Defects
= Trash
= Dirt
=Knocking
= Loose parts = Leaks
=Scattering
=Skips
=Curvature
=Abrasion
=Rust
=Scratches
=Eccentricity
=Lurching
=Abnormal
=Vibration
Movements
=Abnormal
=Heat
=Abnormal
Sounds
smells
=Faded colour =Hisses
34
Seiso = Cleaning
5 Minutes Every day for cleaning
• Devote 5 minutes everyday for cleaning your
work area
• Participation of everyone is required
• Attack hard to clean places regularly
35
Seiso = Cleaning
Cleaning-Inspection points for most
equipment
Grime, clogging, dust balls, rust,
Cleaning leakage etc.
Oils
No oil, Low oil, leakage, filter clogging,
dirty oil, dirty or bent oil lines, clogged
drainage, oil spillage, worn& torn ports
etc.
36
Seiso = Cleaning
Cleaning-Inspection points for most
equipment
Tightening
Heat
Loose bolts, welding detachment,
loose parts, vibration or bumping
noise, friction
Oil tanks, motors, heater, axles, control
panels, washing/ cleaning water,
bearing, wiring etc.
37
Seiso = Cleaning
Cleaning-Inspection points for most
equipment
Breakage,
Cracks
Breakage, cracks, dent on sliding
parts, handle has come off, broken
switches, wire joints come off, wires
are broken or crack, crack dial of
various pre. gauges, meters etc.
38
Seiso = Cleaning
Function wise Cleaning check list of
equipment
Pneumatics
Compressed Air lines, air valves,
connections, meters, filters,
reservoirs etc.
Hydraulics
Hydraulic oil tank, oil valves,
filters, pumps, hoses, gauges,
cylinders etc.
39
Seiso = Cleaning
Function wise Cleaning check list of
equipment
Motor fan, fan belt, couplings,
Mech &
Joints, pulleys, chains, pump
Power Train
bearings etc.
Electrical
Control panel, lamps, light, switch,
sensors, wiring, ducts, fuses etc.
40
Seiso = Cleaning
Function wise Cleaning check list of
equipment
Toolings
Equipment
Specific
Tools, fixtures, gauges, dies,
measuring instruments, etc.
Furnaces, rollers, chutes,
CNC machines, etc.
41
SEIKETSU = Standardization
Meaning
Setting up standards / Norms for a neat, clean,
workplace and details of how to maintain the
norm (Procedure)
Activity
- Innovative visual management
- Colour coding
- Early detection of problem and early action
Success
Indicator
Increase in 5S indicator
42
SEIKETSU = Standardization
Japanese Meaning :
Dictionary meaning
“unsoiled things, purity and cleanliness”
Clean manners ,
Clean cloths, clean politician
It is the proof that 3 S’s are being faithfully
carried out.
43
SEIKETSU = Standardization
Tools used for analysis :
MTTR
MTBF
OEE
44
Seiketsu = Standardization
• Regularizing 5S activities so that
abnormalities are revealed
• Make it easy for everyone to identify
the state of normal or abnormal
condition
• For maintaining previous 3S, deploy
visual management
45
Seiketsu = Standardization
• It has been estimated by scientific
study that 60% of all human activities
starts with sight
• 5S is easy to do once.It is consistency
that is difficult. That is why Visual
Management is so important, so that
everybody will know that there is
some problem. Visual Management
46
Seiketsu = Standardization
What visual control communicates ?
It grabs one or more of our senses in
order to
•
•
•
•
Alert us to an abnormality
Help us recover quickly
Promote adherence and prevention
Enable successful self management
47
Seiketsu = Standardization
Some methods for visual communication







Colour coding
Use of Labels
Danger alerts
Indication where things should be put
Directional arrows/ marks
Transparent covers
Performance indicators
48
Seiketsu = Standardization
Some methods for visual communication
Labels
 Precision management labels
 Inspection labels
 Temperature labels
 Responsibility labels
49
Seiketsu = Standardization
Points to remember in making visual c
control tools
1. Make them easy to see from distance
2. Put the display on the things
3. Everyone can tell what is right and
what is wrong
4. Anybody can follow them and make
necessary corrections easily
5. Work place should look brighter &
orderly
50
Seiketsu = Standardization
Some everyday visual management
examples
 Traffic signal
 Zebra crossing
 In car - Petrol indicator
- Speed indicator
 Direction arrows
 Electric danger sign etc.
51
Seiketsu = Standardization
Some visual communication signs
52
SHITSUKE = Self Discipline
Meaning
Every one sticks to the rule and makes it a habit
Activity
- Participation of everyone in developing good
habits
- Regular audits and aiming for higher level
Success
Indicator
High employee morale
Involvement of all people
53
SHITSUKE = Self Discipline
Japanese Meaning :
Dictionary meaning is
“learning of the manners”
“having manners, dressing neatly” OR
“training children for good customs”
54
SHITSUKE = Self Discipline
Activities :
5S Committee
5S Training
5S Competition / evaluation
5S Month
Posters , Literature etc.
55
Shitsuke = Self Discipline
We need everyone to maintain 5S
guidelines.
To maintain DISCIPLINE, we need
to practice and repeat until it
becomes a way of life.
Discipline is the Core of 5S
56
Shitsuke = Self Discipline
Discipline means making a steady
habit of properly maintaining
correct procedure.
Time and effort involved in
establishing proper arrangement
and orderliness will be in vain if
we do not have discipline to
maintain it.
57
Shitsuke = Self Discipline
Pledge
It shall be my constant effort to
maintain my workplace in good
order by
 Assigning a place for everything
& keeping everything in its place
 Sorting out unwanted material
periodically & discarding them
 Keeping my work area neat &
clean everyday
58
Organization
•
•
•
•
•
Departments into areas
Coordinators at department level
Coordinator at each area level
Training for all
Audit each area and make action
check list
• Implement actions
• Audit and evaluation on continuous
basis
59
Implementation Target
• TOTAL FACTORY
• 400 people/month to be trained
• Every 3 month 25% area will be
covered
60