Lean manufacturing 5S
5S is a philosophy and a way of organizing and managing the workspace and
work flow with the intent to improve efficiency by eliminating waste
5S is the name of a workplace organization method that uses a list
of five Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke.
Transliterated or translated into English, they all start with the letter
"S". The list describes how to organize a work space for efficiency
and effectiveness by identifying and storing the items used, maintaining the
area and items, and sustaining the new order.
Seiri-Sort out
Seiton-Set in order
Seiso-Shine or clean
Seiketsu-Standardize
Shitsuke-Sustain
 |
1. Seiri-Sort out
This means sorting and organizing
the items as critical, important, frequently used items, useless, or items that
are not need as of now. Unwanted items can be salvaged. Critical items should
be kept for use nearby and items that are not be used in near future, should be
stored in some place. For this step,
the worth of the item should be decided based on utility and not cost. As a result of this step, the
search time is reduced.
In order to implement the Seiri stage,
Categorize equipment, tool in
your working place into the following 3 categories
|
Necessary |
Which are mandatory for the daily process Eg. Inspection items, machine check list |
|
Unnecessary |
Which are not used for current process or for particular
day Eg. Old /used cloth, old work instruction |
|
May not necessary |
Which may use occasionally Eg. Tool box, spanner set , align key set |
The concept here is that "Each items has a place, and only one place".
The items should be placed
back after usage at the same place. To identify items easily, name plates and
colored tags has to be used. Vertical racks can be used for this purpose, and
heavy items occupy the bottom position in the racks. Labelling, numbering, zoning for clear
identification of storage areas to keep necessary items .Set necessary items matching with
workflow to minimize unnecessary movement and transportation time.
A properly straightened work area allows the operator to quickly review
and verify that they have everything they need to successfully perform their
task at hand.
Click here to see E-book on 5S priciples
3. Seiso-Shine or clean
The next step is to clean everything in the area and remove any trash. To be effective we must keep the area and any related equipment clean. Dirty process equipment can actually increase the potential for process variability and lead to equipment failure. Lost time due to equipment failure is considered waste and non-value-added time. A dirty area can also contribute to safety issues that have the potential to cause a worker to be injured. Operators should clean their areas at the end of each shift. This involves cleaning the work place free of burrs, grease, oil, waste, scrap etc. No loosely hanging wires or oil leakage from machines. Daily sweeping and mopping of floor, corridor etc. Regular cleaning and maintenance of equipment, tools, machines
4. Seiketsu-Standardize
The fourth step has been called the
most important step in the 5S Process. In this step we must develop the
standards for the 5S system. They will be the standards by which the previous
5S steps are measured and maintained. In this step, work instructions,
checklists, standard work and other documentation are developed. Without work
instructions or standard work, operators tend to gradually just do things their
own way instead of what was determined by the team. The use of visual
management is very valuable in this phase. Color coding and standard colors for
the surroundings are sometimes used. Photos of the area in the standard 5S
configuration are often posted for easier identification of non-conformance.
The operators are trained to detect non-conforming conditions and correct them
immediately. Schedules should also be developed for regular maintenance
activities in each area. These standards are implemented for whole organization
and are tested / inspected randomly.
5. Shitsuke-Sustain
This step in the 5S Process can sometimes become the most challenging of all the five steps. Sustaining is the continuation of the Sort, Straighten, Shine and Standardize steps. It is the most important step in that it addresses the need to perform 5S on a consistent and systematic basis. During this step a standard audit system is usually developed and implemented. The goal of the sustain step is to ingrain the 5S process into the company culture. The company must strive to make 5S a way of life so the benefits gained through the exercise can be maintained. This includes wearing badges, following work procedures, punctuality, dedication to the organization etc.
6’S
The
additional step being applied is safety. The goal of this step is to foster a
culture that enhances safety by identifying any workplace hazards and removing
them. In addition, tools and workstations are selected or designed with proper
ergonomics in mind. The emphasis being that in each of the other 5S steps the
motto is “Safety First”. . A safe working environment positively affects
productivity and quality. A safe workplace creates a stress-free and healthy
atmosphere where all workers feel safe and secure. A clean and organized
workplace can also make it easy to recognize and control potential hazards. Workers
should also wear appropriate Personal
Protective Equipment (PPE) as an additional protection
to hazards which are difficult to control or cannot be eliminated. PPE includes
hard hats, safety goggles, face masks, insulated gloves, slip-resistant boots,
and a lot more.
Why 5S is more important
There are many benefits to implementing the 5S Methods into
a work area on the production line or in the business office. To not only
survive but thrive in business today, cost must be controlled and waste must be
avoided or eliminated. The 5S steps, when implemented properly, can identify
and reduce many forms of waste in any process or workstation. An organized work
area reduces excessive motion and wasted time looking for the right tool. The
visual aspect of the 5S Methodology is also very effective. When
everything has a place, it is easier to spot something missing or misplaced. A
clean work area helps draw attention to possible problems or safety hazards. A
clean floor helps spot any leaks or spills could indicate machine maintenance
and prevent slips and falls. Furthermore, encouraging people to watch for and
address problems can result in a positive change to an organizations culture.
Therefore, the 5S Principles implemented as part of a larger Lean initiative or
as a standalone tool can reduce waste, improve quality, promote safety and
drive continuous improvement.
There are notable benefits in implementing 5S
methodology into a workforce
Saving and recovering the workspace
Minimizing the search time and rearranging the workspace time
Taking a corrective action moves in a faster time
Achieve higher productivity and better quality in performance
Able to perform first in right job every time
Able to perform cost reduction activities in able to promote team force effort
E-book reference links
LEAN: Lean Tools - 5S (Lean, Lean Manufacturing, Lean Six Sigma, Lean 5S, Lean StartUp, Lean Enterprise)
Post a Comment