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Presentation
Title:
Creating World Class Organization through
5S & Visual Management
Presented
on
2nd Feb 2015
@
3rd Annual Lean Conference,
AMA, Ahmedabad
Creating World Class Organizations
Through
5S
& Visual Management
5S is a set of steps to create a more
productive workshop
5 Step to reduce or eliminate waste
• Searching
• Waiting
• Wandering
• Wondering
• Delays
• Extras
• Waste/Scrap
8 Type of Waste
 Transportation
 Motion
 Waiting
 Inventory
Over processing
Rejection
Over production
 Human Potential
× Cleaning and janitorial work
to satisfy management.
× Imposing standards at
workplace.
× Silver bullet to productivity
gains.
 Foundation to achieve
employee engagement ,
waste reduction, improve
workflow, and safety.
 Empower workforce.
 There will not be immediate
influx of ROI when you
implement 5S, but it trickles
down slowly, in different
forms & ways.
“There is not an end, it’s a journey”
5S Pictures
5S Pictures
5S Pictures
s
1st
S - SEIRI
Sorting Out
1. Touch everything
2. Evaluate everything with a standard set of decision
making rules
3. Tag it
4. Set tagged items in tag area
5. Record all items in a Red tag Register
Remove all unessential items from
the workplace
Tools
Red Tag Red Tag Register Red Tag Area
s
2nd
S - SEITON
Systematic
Arrangement
• Identify a home for everything that will be easy to find and
put away (PEEP)
• List everything that’s left from sorting step
• Create a master list of everything include as much in
formation on it as possible
• Agree on a location for these items,
1. How to keep them,
2. How many to keep,
3. Use Visuals to locate them
2nd S: Set in Order
Examples of Seiton
s
3rd
S - SEISO
Spic and Span
• Keep everything in top condition. So, when someone need
something, it's ready
• Designate areas of space to different person
• Remove unnecessary items
• Sweep & wipe down with tools
Shine
Example of Seiso
s
4th
S - SEIKETSU
Standardization
• Take the pictures
• Create a map of that locates where everything is stored
• 5S team maintains a job list and schedule 5S activities
Establish Visuals for everyone to
maintain the condition
Example of Seiketsu
s
5th
S -
SHITSUKE
Self Discipline/
Sustain
• Clear deliverables & communication
• Score Keeping
• Continuous improvement with cyclic mini-5S events
Tools:
• Training and Awareness of 5S
• Dedicated 5S team
• Clear 5S Map and Responsibilities/Ownership
You are setting the standards to
what you must live by
5S Benefits to
Customer & Employees
Customer
• Win customer confidence by
bringing them to factory
• Delight the Customer
• Customers always expect
lower price. 5S is one way to
make it possible
• Faster Response to queries/
requests
• Improves on time delivery
• Higher demands are met
Employees
• Improve employee
involvement
• Lower Absenteeism
• Build Employee pride
• Working smarter not
harder
• Higher employee
Satisfaction
5S Benefits –
Improves, Reduces
Improves
• Productivity
• Quality
• Process Reliability
• Work Standardization
• Work Culture
• Daily & Shift Start Times
• Simplified work Environment
• Profitability & Efficiency by
reducing time wasted looking for
tools and Equipment
• Safety
Reduces
• Transportations
• Cost
• Machine Down time
• Changeover Time
• Lead Time
• Waste
• Inventory
• Rejects/ Rework
• Breakdowns
• Waste in materials, Space &
Time
How to implement 5S
Define Scope
• Where?-Identify where exactly
boundary starts and ends
• Who?- Define the 5S team and
participants with the visuals
• What?- Define the 5S job
responsibility with required
resources?
• When?-Settle down a plan for
5S activities with targetdates
and checklist for routine
How to implement 5S
Define Scope
How to implement 5S ?
Collect Baseline Data
• Use pictures of Before and After (Inside - outside, Above-under)
• Time Study
• Cost & Quality of Inventory
How to implement 5S
Spaghetti Diagram Floor Plan Usage
Use Data
5S - SEITON
5S-SEITON
5S - SEITON
Thank You

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Creating World Class Organization Through 5S and Visual Management @ 3rd Annual Lean Conference, 2015 @ AMA Ahmedabad

  • 1. Presentation Title: Creating World Class Organization through 5S & Visual Management Presented on 2nd Feb 2015 @ 3rd Annual Lean Conference, AMA, Ahmedabad
  • 2. Creating World Class Organizations Through 5S & Visual Management
  • 3. 5S is a set of steps to create a more productive workshop
  • 4. 5 Step to reduce or eliminate waste • Searching • Waiting • Wandering • Wondering • Delays • Extras • Waste/Scrap 8 Type of Waste  Transportation  Motion  Waiting  Inventory Over processing Rejection Over production  Human Potential
  • 5. × Cleaning and janitorial work to satisfy management. × Imposing standards at workplace. × Silver bullet to productivity gains.  Foundation to achieve employee engagement , waste reduction, improve workflow, and safety.  Empower workforce.  There will not be immediate influx of ROI when you implement 5S, but it trickles down slowly, in different forms & ways. “There is not an end, it’s a journey”
  • 10. 1. Touch everything 2. Evaluate everything with a standard set of decision making rules 3. Tag it 4. Set tagged items in tag area 5. Record all items in a Red tag Register Remove all unessential items from the workplace
  • 11. Tools Red Tag Red Tag Register Red Tag Area
  • 13. • Identify a home for everything that will be easy to find and put away (PEEP) • List everything that’s left from sorting step • Create a master list of everything include as much in formation on it as possible • Agree on a location for these items, 1. How to keep them, 2. How many to keep, 3. Use Visuals to locate them 2nd S: Set in Order
  • 16. • Keep everything in top condition. So, when someone need something, it's ready • Designate areas of space to different person • Remove unnecessary items • Sweep & wipe down with tools Shine
  • 19. • Take the pictures • Create a map of that locates where everything is stored • 5S team maintains a job list and schedule 5S activities Establish Visuals for everyone to maintain the condition
  • 22. • Clear deliverables & communication • Score Keeping • Continuous improvement with cyclic mini-5S events Tools: • Training and Awareness of 5S • Dedicated 5S team • Clear 5S Map and Responsibilities/Ownership You are setting the standards to what you must live by
  • 23. 5S Benefits to Customer & Employees Customer • Win customer confidence by bringing them to factory • Delight the Customer • Customers always expect lower price. 5S is one way to make it possible • Faster Response to queries/ requests • Improves on time delivery • Higher demands are met Employees • Improve employee involvement • Lower Absenteeism • Build Employee pride • Working smarter not harder • Higher employee Satisfaction
  • 24. 5S Benefits – Improves, Reduces Improves • Productivity • Quality • Process Reliability • Work Standardization • Work Culture • Daily & Shift Start Times • Simplified work Environment • Profitability & Efficiency by reducing time wasted looking for tools and Equipment • Safety Reduces • Transportations • Cost • Machine Down time • Changeover Time • Lead Time • Waste • Inventory • Rejects/ Rework • Breakdowns • Waste in materials, Space & Time
  • 25. How to implement 5S Define Scope • Where?-Identify where exactly boundary starts and ends • Who?- Define the 5S team and participants with the visuals
  • 26. • What?- Define the 5S job responsibility with required resources? • When?-Settle down a plan for 5S activities with targetdates and checklist for routine How to implement 5S Define Scope
  • 27. How to implement 5S ? Collect Baseline Data • Use pictures of Before and After (Inside - outside, Above-under)
  • 28. • Time Study • Cost & Quality of Inventory How to implement 5S Spaghetti Diagram Floor Plan Usage Use Data